C E M E N T E D C A R B I D E - Fujilloy thailand co., · PDF fileHIP (Hot Isostatic Press)...

C E M E N T E D C A R B I D E

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•Inspection*Check and confirm final goods produced in stable & high quality

•Received order from customer•Design

•Raw material (TungstenCarbide,Cobalt,

Nickl and Other Carbides)•Mixing•Granulation and sieving

•Pressing and Molding

•Sintering •HIP(Hot Isostatic Pressing)•Completion of Cemented Carbide Alloy

Accomplish high efficient tip. Sale as“FUJILLOY Tip”

•Grinding and Cutting Processing

•Wire EDM (Electric Discharge Machining) and EDM

•Polishing

•Packing & Shipment

Uncompromising Product Inspections

FUJILLOY – “Tool for Long Life”

“FUJILLOY” as Trade Mark of Fuji Die Co., Ltd. has always understood “Tools for Long Life”.

FUJILLOY (THAILAND) CO., LTD. was established by Fuji Die Co., Ltd. Japan, and serves overseas customers with “FUJILLOY”quality tools for today and tomorrow.

We, FUJILLOY, are proud of our “Tools for Long Life” in a wide variety for high precision mechanics lead the van of industrial innovation.

We also recommend “FUJILLOY” materials, such as; cemented carbide, ceramics and other products.

High precision instruments require ultra-hard and wear-resistible tools and we, FUJILLOY, prepare flexible answers for your expectation.

We, FUJILLOY, are always ready to respond to you, anywhere and anytime, with the top quality and services in punctual delivery.

All Technology Aiming to Realize Customer Satisfaction - The FUJILLOY Consistent Production System

FDS (Fuji Die Standard) & ISO 9001 Quality management keep the highest precision technology up provided with excellent cemented carbide products. Based on well controlled engineering to adjust material,consistent manufacture in sintering, pressing,product completion, and the final inspection for ultra-precise product has secured.

Production Process of FUJILLOY

Using the world advanced equipment, including surface texture measuring machines boasting high magnifications of 2,000,000 times, FUJILLOY supports customers' advanced requests.* Resolution, output nunits and assured accuracy (Extracted from manufactures' catalogs)

*Produce powder from selected pure material

•Forming

Form-tester(Form-Tracer)

Roundness Measuring Instrument

Profile projector

Gauges(Block gauges, Hight gauges,Bore gauges, Cylindrical gauges and Micrometers) ** λ=633nm

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Drawing Die & Mandrel Powder Compacting Mold for Rotary PressCVD, PVD, DLC Coating tools

Die & Punch for Electronic Parts

Cold Forging Die & Punch

Forming-Roll, Emboss-Roll, Roll for Hot-Rolling Mill

Mold Part for Lens

Ceramic Tool

Die & Punch for Manufacturing Cans

Preform Part of Cemented Carbide

Pot & Plunger for IC-Molding

Electrode of Copper-Tungsten Alloy for EDMSuper Precision Wear-Resistant Tool

Diamond Wheel

Kneading & Extruding Part for Resin

Diamond wheel and Parts for ELID-Grinding-SystemSelf-Lubricating Composite

Powder Compacting Mold

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FUJILLOY Cemented Carbide

Fujilloy (Thailand) Co., Ltd., colleague Fuji Die Group, is the professional manufacturer of wear-resistance & impact-resistance tools in cemented carbide, and we have developed a wide variety of invention in response to customers satisfaction. Fujilloy (Thailand) Co., Ltd. recognizes it our duty offering new technology of supreme cemented carbide to worldwide industries.Let us go together introduce FUJILLOY products.

Identification of Cemented Carbide

Cemented carbide is a general term for 9 sorts (W, Mo, Cr, Ti, Zr, Hf, V, Nb, or Ta) of carbide combined with Fe Group. (Fe, Co, or Ni), among other things, the most popular one is WC-Co alloy.

Superiority of Cemented Carbide

*Improve the detailed and precise of tool dimensions.*Improve the surface condition of tools and outlook of them.*Improve wear-resistance and minify wear-dust mingled into the products. *Improve machinery operation ratio and extend maintenance period.*Above all superiorities contribute the environment.

Characteristic Comparison of Tool Material Variety

Table 1 is properties of various tool material data of cemented carbide of FUJILLOY, and it shows, in particular, high scores for Young's modulus of elasticity and thermal conductivity compared with SKD, SKH and ceramics. FUJILLOY cemented carbide shows superior hardness & compressive strength covering properties from SKD11 to ceramics. FUJILLOY cemented carbide, of which Young's modulus of elasticity shows the highest score among tool materials, proves FUJILLOY the best selection for the plastic working material.

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Service Networks for ASEAN to Worldwide

Fujilloy (Thailand) co-operated with Fuji Die co. Japan works all the way through in pursuit of customers satisfaction serving super hard wear resistant tools in sincere. Fuji Die Group has basemants in ASEAN & China, let alone in Japan, and seeks after good service with punctual delivery.

High Techniques & Capacity

Fuji Die Group is proud of the most excellent techniques and the capacity in wear-resistance tool industry in Japan and also international.

Necessary Data for Cemented Carbide Selection

These are mesured values and aren't standards.Table 1

Passive Material data manufactured by the Tool•Material composition •Shape •Surface condition •Mechanical characteristics

Passive Material data manufactured by the Tool•Working stress (specification of equipment) •Lubricant there is (specification & quantity) •Temperature •Forming speed •Cooling system if there is (specification & quantity) •Operation frequency •Maintenance method

Conventional Tools•Sort of tools •Life time (caused working condition) •Preciseness •Productivity

Others•Related information

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FUJILLOY TIP (As-Sintered Pellets)

We can deliver reliable precision cemented carbide of FUJILLOY tips made in Japan, for any purpose. We can also supply Pre-form Products based on top technology of FUJILLOY.

The Example of a Manufacture Maximum Size of A General Grade Chip

Hard-Tap(Cemented Carbide with Screw Thread)Fuji Die Group proposes cemented carbide tip bored with screw thread called “Hard Tap”, which cut down on fabrication cost and time.

Tapping Green compacts or Pre-sintered compacts and sintering. Fuji Die Group is always ready to supply “Hard Tap” based on your production line and capacity.

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Utilizes pre-form tip material and thus contributes to cost reduction and shortened delivery time to the processing industry.

Technology and supplying capacity are verified by production of 1 million items per year

3-sintering plants strategically located throughout Japan (Koriyama, Okayama and Kumamoto plant) and equipped with 4-HIP units and 40-furnaces.

We also offer HIP Treatment of various materials on consignment basis

Feature

Internal Threads with high toughness

Soldering and electric discharge machining method sometimes make cracks, slips, chips, and distortion but Hard-Tap eliminate such accidents.

Make machines possible to dig internal threads in thin, complex formed and special grade cemented carbide tips.

Usable for hot using tools, for which brazed tips can't be used.

Hard-Tap Features

Test method: Test piece was clamped in a vice and a hexagon head bolt(steel, stainless steel) and a torque wrench were used to check the breakage point.

Test piece: Ultra-hard hard-tap tip Material grade: G65 Screw size: M12

Test result: Steel or stainless steel bolt has broken before the ultra-hard hard-tap chip, thus proving the strength of the latter surpasses that of the former. Torque rate of breakage point is shown in Table 4.

Test Methods and Results

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Hard-Tap Typical Precision

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Torque Rate of Bolt Breakage Point

: Torque limit prior to brakage : Torque at point of bolt brakage (No damage to ultra-hard hard-tap product)

Bolt Brakage point Torque Steel bolt: 257 (N•m) Stainless steel Bolt: 191 (N•m) *Breaking point torque rates differ with bolt material

"Hard-Tap" is hold the same accuracy at electric dischage machining of chips

Table 2

Table 3

Table 4

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*1 Vickers indentation methode on Niihara's formula.*2 Wear resistance testing by ASTM B611-76. Load 10kg Wheel FC20 Aluminum oxide Slurry *3 Corrosion resistance As for the usual solution test , Cl- is 3000ppm, PH3 with sodium citride solution (24hr)

is stock is available is now testing

Mechanical Property

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We might not produce due to fuzzy form and dimension. We are much appreciated that you would ask the inquiry in details. And about the grade whose name starts from T except T15, we need to discuss with you about the delivery term and other conditions. before acceptance of orders.

Up to 09/20/2007 This document does not show standard values, but shows representative examples. We would change them without notice.

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Hardness of cemented carbide varies resistance by WC grain size and Co content. The grain size finer and Co content lower, alloy shows harder feature. FUJILLOY ultra fine grained cemented carbide shows less defect and rather higher figure of TRS because almost of them passed through HIP treatment.

HIP treatment gives cemented carbide the press strengthen with the high temperature and high atmospheric pressure in inert gas circumstance. Pores remained a few numbers in cemented carbide shall surely put off through HIP treatment.

With regards to above HIP treatment, only upper than 10% of Co contained FUJILLOY cemented carbide (such as material sort of D40 D60, G & C-series) is free from HIP treatment though other cemented carbides have to pass HIP process, and with shorter delivery.

It is because we succeeded pores dimension smaller than WC grain size, then those materials have enough strength without HIP treatment.

HIP (Hot Isostatic Press) Treatment

Fig. 1 TRS of FUJILLOY before and after HIP

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Micro-grained hard alloys with WC grains less than 0.5µm. These alloys show extremely high hardness, compressive strength and resistance to wear.

Super & Ultra Fine Grade F-series

F10

These fine-grained hard alloys, consisting of WC grains of approximately 1µm, have the properties of both wear resistance and toughness. For general propose use, their performance has been excellent.

Fine GradeN-series

N10

Grades sui table for tools requiring toughness and anti-tipping quality; their properties fall midway between D- and C-series.

Medium Coarse GradeG-series

T h e s e u n i v e r s a l g r a d e s suitable for miscellaneous manufacturing tools have the properties of superior wear resistance and toughness.

Medium GradeD-series

D40

Grades suitable for tools like hot forging-equipment that require toughness and mechanical or thermal shock resistance.

Coarse GradeC-series

C60

Cr is added to Co-Ni alloy binder for toughness, high thermal shock and corrosion resistance; suitable for tools used at relatively high temperatures.Adequate grades for forming roll in high temperatures up to 800°C

Super Coarse GradeU-grade

U61

G55

10µm

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In general,it is said cemented carbide is weak for oxidation but FUJILLOY achieved to improve it, especially heavy alloy FHR96 based tungsten shows comparative superior characteristic to oxidation.

Fig. 4 Results of Oxidation Test (at 800°C, 30min, in the air)

Co content becomes lower and gra in s ize becomes bigger, thermal conductivity shows higher feature.In case of easy seizing occurred risk forecasted, it is necessary to consider thermal conductivity at material selection.

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Fig. 3 Relationship between thermal conductivityand WC grain size of FUJILLOY

WC gra in s ize becomes smaller, △ T becomes lower. It is necessary to beware of this point for tools used in the high temperature atmosphere.

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Fig. 2 Relationship between thermal shook resistant temperature (△T) and WC grain size of FUJILLOY

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Higher thermal shook resistance Thermal conductivity increase

Heat resistance increase

Hardness higherSurface abrasion decrease

Compressive strength increase

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Main Character

Transverse Rupture Strength (TRS) figure of FUJILLOY shows less relationship with its hardness by the data of Fig.5. On the contrary, Fracture toughness (K1C) data of FUJILLOY and the hardness figures are strongly related as shown in Fig.6. Fracture toughness (K1C) figure gives rather effective data of material toughness complied with the dynamic stress. Considering K1C & hardness figures which instruct wear resistance level, material selection based on the balance of toughness and wear resistance would be available.

Fig.7 shows abrasion data of typical FUJILLOY materials measured in accordance with ASTM B611 method. It is conceded that wear resistance level is measured in hardness data. Referring abrasion data by ASTM method, further data of wear resistance level for scoring would be obtained.Fig.8 is the corrosion resistance (Rcorr) data and which appoints higher Rcorr ones show higher wear resistance. It is recognized cemented carbide shows superior characteristic than that of steel material in corrosion resistance and there prepared material concentrated specially in anti-corrosion for required use.

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Fig.5: FUJILLOY TRS & Hardness Fig.6: FUJILLOY Fracture toughness (K1C) & Hardness

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Fig.7: FUJILLOY Abrasion Fig.8: FUJILLOY Corrosion resistance

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Medium Coarse Grade(WC-Ni)

MG95

Super Fine Grade(WC-Ni)

MF10

Hardness higherSurface abrasion decrease

Strength increase

Toughness increase

Medium Grade(WC-Ni)

Medium Grade(WC-Ni)

M50

Medium Grade(WC-Ni)

M70

Non-Magnetic and also Satisfactory Corrosion Resistance FUJILLOY MF10, M45, M70

Micrograph samples of cemented carbide

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M45

Table 5: Corrosion Resistance of M-serise

Table 6: Magnetic permeability of M-serise

M50 is non-magnetic characteristic and suitable for wide range of manufacturing parts.

MG95 with WC-Ni shows high toughness characteristic.

FUJILLOY is the pioneer of micro-grained cemented carbide with WC-Ni and called MF10 brand, which is remarkable fruit from FUJILLOY, meets with public approval.

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10µm

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Suitable Grade for W-EDM Process V-series

Among similar hardness range of FUJILLOY, V-series show better figures of fracture toughness and corrosion resistance. V-series get few micro-cracks in electric discharge machining, and show strong corrosion resistance.

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F20 VF12

TVG60

Improve Toughness

Improve Hardness

VD45

These photographs show typical feature through anti-corrosion test under the rather corrosive circumstance

Photo 1: Comparison of microstructures near surface after W-EDM

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Fig.9: Fracture toughness K1C (MPa•m1/2)

Table 7: Comparison with Variety of V-series and other FUJILLOY grades showing similar hardness

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FUJILLOY Grinding Technique

The hardest grade among FUJILLOY cemented carbide, such as ultra fine grained, requires severe grinding condition control.Resin bonded diamond wheel with density range 3.3---3.96 ct/cc is suitable for cemented carbide which hardness is over than 90HRA.Table 8 shows typical case of grinding conditions used FUJILLOY standard type resin bonded diamond wheel. Careful treatment to rough grinding work is required for fine grained type and the hardest type because they are easy to get chipping.

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Typical Grinding Condition

At the finishing work, those types of material appear another trend. Photo 2 & 3 show the ground face and edge of a test piece treated in accordance with the finishing grinding condition mentioned in Table 8. Each photo appears WC grain size and Co content ratio efficiency.These photos appeal that grain size become finer, surface roughness and chip defect ratio on edges become smaller.And effected by the certain level of Co content prevents surface roughness and chip defect ratio of edges.Those phenomena are recognized as related to fracture toughness and tensile strength.It means that ultra fine grained cemented carbide with high tensile strength, and which alloy was ground as finishing condition, is suite for the blanking punch tools to which sharp edges are required.

Photo 2: Both edge condition with WC grain size of WC-(XC)-10%Co alloy after grinding

Photo 3: Both edge condition with Co content of WC-(XC)-10%Co alloy (WC grain size 1.5µm) after grinding

0.5µmWC grain size 1.5µm 2.9µm 3.8µm

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Table 8

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FUJILLOY EDM ( Electrical Discharge Machining) Techniques

It is necessary to minimize microscopic cracks mentioned as bellows.

1) Lower lp value, and control fabrication speed slower 50% than standard method. 2) Use diameter less than 0.2 wire electrodes and restrain fabrication power. Above condition shown in Table 9

Fig.10 shows TRS (transverse rupture strength) comparison data in related with grain size and Co content when material is fabricated by grinding method and 3 types of wire cut electric discharge machining (W-EDM) method shown in Table 10. FUJILLOY cemented carbide property; In case of grinding method, WC grain sizes become finer, TRS become bigger. Incase of W-EDM method, WC grain sizes become finer, TRS become smaller in any type of 3 methods. Particularly WC grain size 0.5µm range, it shows obvious lower figures of TRS. Finer grain alloy is easier to get fine cracks pointed by arrow in photo 4(a). Bigger grain alloys also get them but limited to degenerate stratum shown by arrow in photo 4(b). Above should be considered for selection of tool strength.

TRS shall be recovered to original value by taken off degenerate stratum, which was caused by electric discharge machining, through grinding process.

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Table 9: Typical W-EDM condition

Table 10: Surface roughness after W-EDM

Photo 4: Fracture point of WC-(XC)-10%Co cemented carbide after W-EDM process

Fig.10: TRS variation by surface processing method related with WC grain size & Co content

(a) WC grain size 0.5 µm (b)WC grain size 2.5 µm

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CVD Coating

CVD(Chemical Vapor Deposition) coating means making 4-8µm film on the material at 800-1,000°C atmosphere .

FUJILLOY has 3 categories of film coat stuff [TiC (Titanium Carbide), Ti(C, N) (Titanium Carbide Nitride), TiN (Titanium Nitride)] and 3 types of coating method [single, double, triple]

FUJILLOY casts about process control of CVD and succeeded to find out a strong adherent film in minute density method.

Cemented carbide can increase wear resistance peculiarity with CVD coating, but decreases TRS. Fig.11 shows that, stratum becomes thicker, TRS becomes lower. And also the grain size becomes finer, TRS becomes lower. It is necessary to consider above points when making up tools idea.Surface roughness of CVD coating is hard to polish, and it is said, in general, that CVD coating surface roughness is inferior to that of cemented carbide.

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Table 13: Grade of PVD coating

Table 12: Typical characteristics of coating film

Table 14: Caution about PVD coating

Fig.11: TRS and CVD coating thickness

Table 11: FUJILLOY CVD coated film characteristics

FUJILLOY developed DLC (Diamond Like Carbon) coating, which shows less friction and less seizing and adopted FUJILLOY own brand tools. There are 2 types of DLC method. DLC-I for high excoriation resistance and DLC-R for less friction usage.PVD coating (CrN, TiN, Ti(C, N)) by AIP (Arc Ion Plating) method also adopted FUJILLOY own brand tools. AIP method is to produce the film through flying off ion in vapor by electric arc spark from evaporating metal source as the cathode in a vacuum and that operation does not require difficult handlings. Material attachment and other preparation are easy.

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FUJILLOY (THAILAND) CO., LTD.

Address: No.302 88/5 MOO 3, TAMBOL TAKAM, AMPHUR BANGPAKONG, CHACHOEGSAO 24130 THAILANDTEL: +66-38-573-497 FAX: +66-38-573-499E-mail: [email protected]

OKAYAMA PLANT8234-15 SIN-MINATO, OTOSHIMA TAMASHIMA, KURASIKI, OKAYAMA, JAPAN

MIE FACTORY293-6 OKA, HAKUSAN, TSU, MIE, JAPAN

KAINAN FACTORY260-68 FUNAO, KAINAN, WAKAYAMA, JAPAN

MOJI FACTORY3-3-7 KUZUHA, MOJI-KU, KITAKYUSYU, FUKUOKA, JAPAN

KUMAMOTO PLANT1966 SEKISHITA NANKAN, TAMANA, KUMAMOTO, JAPAN

FUJI DIE TRADING (SHANGHAI) CO., LTD2299 YAN AN ROAD WEST, SHANGHAI, SHANGHAI WORLD TRADE CITY 10A-27/29 CHINA

FUJI DIE Groups (FUJI DIE CO., LTD)

Registration No. : 12954600118Registered Date : November 24, 2003Founded: December 6, 2003BOI Approval: January 27, 2004Received BOI Certificate : March 8, 2004Paid in Capital : 21,000,000 THB (100% ownd by Fuji die Co., Ltd.)

HEAD OFFICEAddress: 2-17-10 SHIMOMARUKO, OTA-KU, TOKYO, JAPANTEL: +81-3-3759-7181 FAX: +81-3-3756-0290

FACTORYKORIYAMA PLANT2-2-8 MACHIIKEDAI, KORIYAMA, FUKUSHIMA, JAPAN

SAITAMA FACTORY4-21-27 HIZAORE, ASAKA, SAITAMA, JAPAN

HADANO FACTORY41-2 HIRASAWA, HADANO, KANAGAWA, JAPAN

NAGOYA FACTORY10-1 ONEYAMA, ODAKA, MIDORI-KU, NAGOYA, AICHI JAPAN

OSAKA FACTORY8-10 YOSHINO, SUITA, OSAKA, JAPAN

11.2007-TH Printed in Thailand

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