Cost-Effective Pilot-Scale Production and Characterization of ESR- Refined Hot-Work Tool Steel for Forging Die Applications
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The present study proposes and validates a cost-effective and industrially scalable route for producing high-performance hot-work tool steel for forging die applications. Unlike conventional electric arc furnace (EAF) – ladle furnace (LF) – vacuum degassing (VD) routes, the steel was produced using hot-work tool steel scrap melted in a pilot plant open-air induction furnace (IF), followed by electro-slag remelting (ESR). Steel composition (0.6%C, 012%Si, 0.6%Mn, 0.01%P, 0.02%S, 1.16%Cr, 0.48%Mo, 1.55%Ni, 0.07%V and 0.007%N) was achieved with minimal alloying additions. Thermodynamic simulations using Thermo-Calc were employed to predict phase evolution and optimize processing parameters. The ESR process significantly improved steel cleanliness, reduced segregation, and refined inclusion morphology. Subsequent hot forging and optimized heat treatment produced a homogeneous tempered martensitic microstructure with fine carbide dispersion. The steel exhibited a hardness of 46.6 HRC, tensile properties of UTS:1413 MPa, YS:1283 MPa, TE: 8.2%, compression strength 2450 MPa, compressive ductility 41%, and impact toughness of 24 J. The results demonstrate that the proposed route provides a viable alternative for producing high-quality hot-work tool steels with improved cost efficiency and performance.
