TSFX44 High-Wear-Resistance High-Toughness Spray-Formed Steel

I. Chemical Composition and Characteristics

Key Properties and Application Areas: As a counterpart to Uddeholm's Vanadis® 4 Extra SuperClean powder metallurgy steel, our company has developed corresponding grades for different melting processes: powder metallurgy grade TPMB44, electroslag remelted (ESR) grade TGC99, and spray-formed grade TSFX44. These materials offer an exceptional combination of high impact toughness and excellent wear resistance. They are suitable for fine blanking, powder compaction tooling, processing of high-strength low-alloy (HSLA) steels and advanced high-strength steels (AHSS), as well as applications requiring a balance of strength, wear resistance, and toughness. Compared to powder metallurgy steels, TSFX44 offers lower cost and superior wear resistance; compared to ESR steels, it provides higher toughness and better wear resistance.

II. Microstructure (Cross-Section Comparison)

In large-section blocks of TSFX44, the utectic carbides are uniformly distributed, rated at Class 0, reaching the level of powder metallurgy steels. Coarse carbides are finely and dispersedly distributed, with slightly larger sizes than those in powder metallurgy steels, contributing to higher wear resistance. Compared to ESR steels, TSFX44 exhibits a more uniform microstructure, lower brittleness, and reduced risk of mold cracking, offering higher toughness. It is therefore more suitable for applications requiring relatively high toughness and high wear resistance.

III. Impact Toughness (J)

IV. Mechanical Property Comparison

V. Wear Resistance Test

Tests were conducted under identical parameters: using boron nitride (hardness 80–90 HRC) as the abrasive medium, with a test force of 100 N, rotational speed of 100 rpm, duration of 30 minutes, and without heating. TSFX44 demonstrated an 18% improvement in wear resistance over the powder metallurgy grade and a 28% improvement over the ESR grade.

VI. Conclusions

1. In terms of microstructure, mechanical properties, impact toughness, and wear resistance, compared to conventional ESR steels, TSFX44 exhibits a more uniform microstructure, lower risk of quench cracking, finer and better-shaped carbides, lower brittleness, and higher wear resistance. It is better suited for applications demanding high strength, high toughness, and high wear resistance.

2. Compared to powder metallurgy steels, TSFX44 offers higher wear resistance and lower cost, though its toughness and strength are slightly inferior. It is therefore ideal for cost-effective applications that prioritize high wear resistance and do not require the highest levels of strength and toughness.