PHOTO-ETCHING OF TOOL STEEL

SS-EN ISO 9001SS-EN ISO 14001

ContentsThe photo-etching process ........................ 3

Advantages of textured surfaces .............. 3

Test programme ........................................ 4

Summary .................................................. 7

This information is based on our present state of knowledge and is intended to provide generalnotes on our products and their uses. It should not therefore be construed as a warranty ofspecific properties of the products described or a warranty for fitness for a particular purpose.

Classified according to EU Directive 1999/45/ECFor further information see our “Material Safety Data Sheets”.

Edition 4, 12.2007The latest revised edition of this brochure is the English version,which is always published on our web site www.uddeholm.com

PHOTO-ETCHING OF TOOL STEEL

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IntroductionA wide variety of moulded parts areproduced with a patterned or texturedsurface. Normally, the pattern is repro-duced on the moulding surfaces of thetool by the photo-etching process.

The photo-etchingprocessPublished information about thetechniques employed by the specialistphoto-etching companies is very limited.Essentially, however, the requiredpattern is transferred to the mouldingsurface by a photographic process. Thepattern is then etched to the requireddepth by the application of an appro-priate acid, under closely controlledcondition.

Photo-etching can be performedboth on complete tools or on specifiedareas of the tool only.

Photo-etching enables a wide varietyof different patterns to be produced invirtually any tool. The patterns may

Advantages oftextured surfacesA textured surface hides minor surfaceflaws which may occur in manufactureor during further treatment and fitting.Because of this, the rejection rate forthe finished products is lower. Moreover,photo-etching replaces the lengthy andexpensive finish polishing process.

The product is given an aestheticallyattractive surface finish. The surface iseasier to grip than a bright surface,which facilitates holding and handling.Irritating reflections are largely avoided.

A further advantage is that finger printsand similar marks do not show up asmuch as on a bright surface.

This brochure deals with photo-etching as a finishing process, with thepossibilities offered by it and with thefactors which must be taken intoaccount to ensure a satisfactory result.These factors were determined by a testprogramme carried out with thecooperation of a leading photo-etchingcompany.

resemble leather or wood graining, forexample, or be a straight forward linepattern with varying directions anddepths. Typical applications are for carinterior fittings, etc., and plastic casingsfor different kinds of machines andinstruments. In recent years, photo-etching has become an increasinglypopular and practical method forimparting attractive and appealingsurfaces to different products.

Textured mould and moulded part for automobile steering wheel.

PHOTO-ETCHING OF TOOL STEEL

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Test programmeTo ensure that the toolmaker and thetool-user gets the optimum results fromUddeholm tool steels that are photo-etched, Uddeholm Tooling has carriedout a series of tests. The test pro-gramme examined a number of influ-encing factors, including:• Photo-etching of different tool steel

grades, annealed and hardened• Flame-hardening, welding and EDM• Grain flow direction of the tool steel• Variations in steel analysis and

cleanliness• Material size

Several different tool steels werestudied, by etching plates measuring50 x 60 mm (2" x 2 1/4"). All surfaceswere ground with a 280-grain grindingwheel. In one set of tests, all the speci-mens were etched under identicalconditions in order to grade the ‘‘etch-ability’’ in terms of the amount of stockremoved from the different material.After this, etching conditions werevaried with the aim of producing opti-mum etching results.

The steels listed below have beenexamined in the first instance aslongitudinal specimens (in the rollingdirection of the material) in the soft-annealed state and also according tothe parameters shown in the chart.

Photograph of a patterned surface.

PHOTO-ETCHING OFDIFFERENT STEEL GRADES

Results

The etching results were assessedtaking into account the etching depth,pattern similarity, side-etching effectand surface appearance. The surfaceshave not only been visually appraisedbut also examined at a high magnifica-tion in order to detect and study anymicroscopic differences.

Soft-annealed Hardened to 55 HRC

Uddeholm Stavax ESR textured with special media.

Uddeholmsteel grade AISI Other parameters studied

RIGOR A2 Hardness: 60 HRCHigh retained austenite content.

CALMAX Hardness: 57 HRC

ORVAR SUPREME H13 Hardness: 52 HRCRough- and fine-spark-machined.

IMPAX SUPREME P20 Analysis variation.Flame-hardened to 54 HRC.Surface and centre of large dimension.Welded with IMPAX electrode.

STAVAX ESR 420 Hardness: 300 HB 55 HRCWelded with STAVAX electrode.

ELMAX Hardness: 58 HRC

Annealed material

Depending on the type of etchingmethod used, a special etching mediamay be needed when etching steelswith good corrosion resistance. This isvalid for Uddeholm Stavax ESR, Udde-holm Mirrax ESR, Uddeholm Corrax and

Uddeholm Elmax. However, owing to itsalloy content also Uddeholm OrvarSupreme and Uddeholm Calmax givesweaker etching than other grades whenthe standard media is used and in viewof this the special media is recom-mended.

PHOTO-ETCHING OF TOOL STEEL

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Flame-hardened material

The influence of flame-hardening onthe etching of Uddeholm Impax Su-preme was also studied and here thereis a decided difference between thelocally hardened zone and the hard-ened and tempered basic material. Inthe flame-hardened zone, a faintstreakiness similar to that in hardenedspecimens is discernible. In addition,there is a difference in etching depthbetween flame-hardened and hardenedand tempered material.

The other steels examined show goodresults upon visual examination afterhaving been etched by the standardprocess. When the surfaces are exam-ined under the microscope (9 x magnifi-cation), some minor differences can beobserved.

The observed differences normallyhave no practical significance. Theynevertheless show that if a tool withinserts which are to be etched with thesame pattern is being made it is advis-able for material from the same bar orblock to be used in all parts in order toget a pattern of identical and uniformappearance on the moulding. (See‘‘Grain flow direction of the tool steel’’,page 6.)

Hardened material

All grades were examined in the fullyhardened condition. Here, too, the fourgrades Uddeholm Orvar Supreme, Udde-holm Calmax, Uddeholm Stavax ESRand Uddeholm Elmax differ from theothers in respect of etchability.

When the surfaces are studied underthe microscope, some tendency tostreakiness is discernible in some of thehardened specimens. The streaks areparallel to the direction of rolling, andthe phenomenon is an expression of thenormal rolling direction which appearsin alloyed tool steels. The streakiness,however, is of such modest proportionthat it lacks significance when usingtool steels with normal degrees of seg-regation, but at the same time it dem-onstrates the importance of selecting asteel that is as homogeneous and uni-formly worked as possible.

The presence of a high content ofretained austenite in a hardened tool isnormally a disadvantage. Etchability,however, is not affected even by a rela-tively high content of retained austeniteaccording to a test performed on Udde-holm Rigor.

Nitrided material

When a tool or insert is to be nitrided,this must be done after photo-etching. Photo-etching on a rough-sparked surface.

Basic material. Flame-hardened zone.

the response to etching will varybetween the weld and the base metaland this will result in a witness mark onthe plastic component. Welds in Udde-holm Impax Supreme, Uddeholm StavaxESR, Uddeholm Mirrax ESR and Udde-holm Calmax with Impax Weld, StavaxWeld or Calmax Weld (or TIG-Weld) orCorrax TIG-Weld will normally not bediscernible after photo-etching.

More information on welding is givenin the brochure ‘‘Welding of Tool Steel’’.

Areas which have been welded shouldalways be clearly indicated to the photo-etching company.

Electrical discharge machining(EDM)

If EDM is not carried out in the rightway, some defects may remain in thesurface of the material. The influence ofspark-erosion on photo-etchability hastherefore been studied. Specimens withboth a rough-sparked and a fine-sparkedsurface were tempered at 250°C (480°F).Photo-etching on a rough-sparkedsurface gives a very poor result. Evenafter a careful fine-sparking operation,it may be difficult to get an acceptableresult.

Flame-hardening, therefore, shouldbe carried out after photo-etching,wherever possible.

Welding

In certain circumstances it may benecessary to weld a tool, for instancefor repair purposes. Welding alwaysseverely affects the uniform structure ofthe parent material.

The weld metal and the base steelmust be similar in composition if awelded surface of a plastic mould is tobe textured via photo-etching. If not,

PHOTO-ETCHING OF TOOL STEEL

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Tempering does not give an appreciableimprovement. If doubts are entertainedas to how the spark-machining hasbeen carried out the material shouldalways be ground or polished to removeany residual traces of the sparking.Special test kits are available for check-ing removal of residual effects afterspark-erosion.

Areas which have been spark-erodedshould be clearly indicated to thephoto-etching company.

The photograph showsstreakiness in photo-etchingof a pre-hardened mould steelwith high sulphur content.

VARIATIONS IN STEELANALYSIS AND CLEANLINESS

There are always minor differences inthe analysis of every steel to occur fromone heat to another. In this context,two extremes in the analysis of Udde-holm Impax Supreme were examined,but no differences in the results of theetching were observable. Normal varia-tions in analysis of Uddeholm Toolingtool steels thus have no influence onphoto-etchability.

The cleanliness of the steel, andespecially its sulphur content, can affectthe appearance of photo-etched pat-terns. Uddeholm Impax Supreme pre-hardened mould steel is particularlysuitable for photo-etching for two rea-sons: it has a very clean microstructure,being subjected to a vacuum degassingprocess during manufacture; it also has

Grain flow directionof the tool steel

Calmax has been examined on both thelengthwise and crosswise direction inthe soft-annealed state. No appreciabledifference between the specimens wasobserved. For fine patterns, however,experience shows that some differencecan occur. Where it is important thatphoto-etched patterns on differentmould parts match exactly, e.g. whenusing inserts, the following procedure isstrongly recommended:

1. Make all parts to be textured fromthe same bar or block of steel

2. Make sure that all surfaces to betextured have the longitudinal grainflow in the same direction

MATERIAL SIZE

When manufacturing materials in heavysections differences in the microstruc-ture of the material can be observedbetween the surface and the centre.In order to study the influence of thesedifferences on the photo-etchability ofImpax Supreme in the size 500 mm(20") dia., specimens from the surfaceand centre were photo-etched.

Surface. Centre.Uddeholm Impax Supreme Ø 500 mm (20").

No differencebetween the twospecimens wasobservable.

A wood-grain textureon a moulded handle fora saucepan.

a very low sulphur content (max.0,010%).There are, however, similar types ofsteels with far higher sulphur contents(0,08%), which can give rise to streaki-ness in photo-etching, as evident fromhe following photograph.

PHOTO-ETCHING OF TOOL STEEL

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SummarySeveral different grades of UddeholmTooling tool steels have been tested forphoto-etchability. The results of theetching tests and other experiencegained can be summarized as follows:

• All of the grades examined can bephoto-etched with satisfactoryresults. There are certain microscopicdifferences, but these normally haveno practical significance whatsoever.

• Uddeholm Orvar Supreme, UddeholmCalmax, Uddeholm Stavax ESR,Uddeholm Mirrax ESR and UddeholmElmax should be etched by a specialprocess.

• If nitriding is to be carried out it mustbe done after photo-etching.

• Flame-hardening prior to photo-etching should be avoided, since thepattern will be etched differently inthe flame-hardened zone and inhardened and tempered base mate-rial.

• A welded tool can in certain circum-stances be photo-etched, but this isconditional upon using the samematerial in the weld as in the parentmaterial.

• Spark-machined surfaces should beground or polished in order to be onthe safe side. A poor etching resultwill be obtained on surfaces marredby residual traces of spark-machin-ing.

• Areas of tools which have beenflame-hardened, welded or spark-eroded should always be clearlyindicated to the photo-etching com-pany.

Part of an automobile steeringwheel produced from a photo-etchedUddeholm Impax Supreme mould.

Photo-textured body for Polaroid instant camera.Mould material: Uddeholm Stavax ESR.

• If several parts are included in a tooland are to be photo-etched withexactly the same pattern, the samegrade of material and the same grainflow direction should be chosen forall the parts.

• Normal variations in analysis for thesame grade of steel have no adverseinfluence. Steels with a clean micro-structure and low sulphur contentgive the most accurate and consist-ent pattern reproduction.

• Different sizes of starting material ofone and the same grade do notusually show any differences.

• Initial machining operations shouldbe followed by stress-relieving priorto finish-machining.

• Coarser abrasives than 220 grainmust not be used on surfaces whichare to be photo-etched.

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EuropeAustriaRepresentative officeUDDEHOLMAlbstraße 10DE-73765 NeuhausenTelephone: +49 7158 9865-0www.uddeholm.de

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Branch officesASSAB Tooling (Beijing) LtdDalian Branch8 Huanghai Street, Haerbin RoadEconomic & Technical Develop. DistrictDalian 116600, ChinaTelephone: +86 411 8761 8080

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Branch officesASSAB Tooling (Dongguan) Co LtdNorthern DistrictSong Shan Lake Science & TechnologyIndustrial ParkDongguan 523808, ChinaTelephone: +86 769 2289 7888www.assabsteels.com

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ASSAB Sripad Steels LTD19X, D. P. P. RoadNaktola Post OfficeIN-Kolkata-700 047Telephone: +91 (33) 400 1645www.assabsripad.com

ASSAB Sripad Steels LTDGround floor, Plot No 11-6-8Opp IDPL Factory Out GateBalanagarIN-Hyderabad-500 037Telephone: +91 (40) 2377 8148www.assabsripad.com

IndonesiaHead officePT ASSAB Steels IndonesiaJl. Rawagelam III No. 5Kawasan Industri PulogadungJakarta 13930, IndonesiaTelephone: +62 21 461 1314www.assabsteels.com

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Branch officesSURABAYA BRANCHJl. Berbek Industri 1/23Surabaya Industrial Estate, RungkutSurabaya 60293, East Java, IndonesiaTelephone: +62 31 843 2277

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JapanUDDEHOLM KKAtago East Building3-16-11 Nishi ShinbashiMinato-ku, Tokyo 105-0003, JapanTelephone: + 81 3 5473 4641www.assabsteels.com

JordanENGINEERING WAY Est.P.O. Box 874Abu AlandaJO-AMMAN 11592Telephone: +962 6 4161962engineeringway@assab.com

MalaysiaHead officeASSAB Steels (Malaysia) Sdn BhdLot 19, Jalan Perusahaan 2Batu Caves Industrial Estate68100 Batu CavesSelangor MalaysiaTelephone: +60 3 6189 0022www.assabsteels.com

Branch officesBUTTERWORTH BRANCHPlot 146aJalan Perindustrial Bukit Minyak 7Kawasan Perindustrial Bukit Minyak14000 Bukit Mertajam, SPT PenangTelephone: +60 4 507 2020

JOHOR BRANCHNo. 8, Jalan Persiaran TeknologiTaman Teknologi81400 SenaiJohor DT, MalaysiaTelephone: +60 7 598 0011

New ZealandVIKING STEELS25 Beach Road, OtahuhuP.O. Box 13-359, OnehungaNZ-AucklandTelephone: +64 9 270 1199www.ssm.co.nz

PakistanASSAB International ABP.O. Box 17595Jebel AliAE-DubaiTelephone: +971 488 12165www.assab.se

PhilippinesASSOCIATED SWEDISH STEELSPHILS Inc.No. 3 E. Rodriguez Jr., AvenueBagong Ilog, Pasig CityPhilippinesTelephone: +632 671 1953/2048www.assabsteels.com

Republic of KoreaHead officeASSAB Steels (Korea) Co Ltd116B-8L, 687-8, Kojan-dongNamdong-kuIncheon 405-310, KoreaTelephone: +82 32 821 4300www.assabsteels.com

Branch officesBUSAN BRANCH14B-5L, 1483-9, Songjeong-dongKangseo-ku, Busan 618-270, KoreaTelephone: +82 51 831 3315

DAEGU BRANCHRoom 27, 7-Dong2 FIndustry Materials Bldg.1629Sangyeog-Dong, Buk-KuKorea-Daegu 702-710Telephone: +82 53 604 5133

LebanonWARDE STEEL & METALS SARL METCharles Helou Av, Warde BldgP.O. Box 165886LB-BeirutTelephone: +961 1 447228lebanon@assab.com

Saudi ArabiaASSAB INTERNATIONAL ABP.O. Box 255092SA-Riyadh 11353Telephone: +966 1 4466542assab@emirates.net.ae

SingaporeHead office PacificASSAB Pacific Pte Ltd171, Chin Swee RoadNo. 07-02, SAN CentreSG-Singapore 169877Telephone: +65 6534 5600www.assabsteels.com

JurongASSAB Steels Singapore (Pte) Ltd18, Penjuru CloseSG-608616 SingaporeTelephone: +65 6862 2200

Sri LankaGERMANIA COLOMBO PRIVATE Ltd.451/A Kandy RoadLK-KelaniyaTelephone: +94 11 2913556www.iwsholdings.com

SyriaWARDE STEEL & METALS SARL METCharles Helou Av, Warde BldgP.O. Box 165886LB-BeirutTelephone: +961 1 447228lebanon@assab.com

TaiwanHead officeASSAB Steels (Taiwan) Co LtdNo. 112 Wu Kung 1st Rd.Wu Ku Industry ZoneTW-Taipei 248-87, Taiwan (R.O.C.)Telephone: +886 2 2299 2849www.assabsteels.com

Branch officesNANTOU BRANCHNo. 10, Industry South 5th RoadNan Kang Industry ZoneNantou 540-66, Taiwan (R.O.C.)Telephone: +886 49 225 1702TAINAN BRANCHNo. 180, Yen He Street,Yong Kang CityTainan 710-82, Taiwan (R.O.C.)Telephone: +886 6 242 6838

ThailandASSAB Steels (Thailand) Ltd9/8 Soi Theedinthai,Taeparak Road, Bangplee,Samutprakarn 10540, ThailandTelephone: +66 2 385 5937,+66 2 757 5017www.assabsteels.com

United Arab EmiratesASSAB INTERNATIONAL ABP.O. Box 17595Jebel AliAE-DubaiTelephone: +971 488 12165www.assab.se

VietnamCAM Trading Steel Co Ltd90/8 Block 5, Tan Thoi Nhat WardDistrict 12, Ho Chi Minh CityVietnamTelephone: +84 8 5920 920www.assabsteels.com

Other AsiaASSAB INTERNATIONAL ABBox 42E-171 11 Solna, SwedenTelephone: +46 8 564 616 70www.assab.se

AfricaEgyptMISR SWEDEN FORENGINEERING IND.Montaser Project No 20Flat No 14Al Ahram Street-El TabiaEG-Giza CairoTelephone: +20 2 7797751www.assab.se

KenyaSANDVIK Kenya LtdP.O. Box 18264Post code 00500KE-NairobiTelephone: +254 20 532 866info@sandvik.co.ke

MoroccoMCM Distribution4 Bis, Rue 8610 - Z.I.2035 Charguia 1TN-TunisTelephone: + 216 71 802 479

South AfricaUDDEHOLM Africa (Pty.) Ltd.P.O. Box 539ZA-1600 Isando/JohannesburgTelephone: +27 11 974 2791www.bohler-uddeholm.co.za

TunisiaMCM Distribution4 Bis, Rue 8610 - Z.I.2035 Charguia 1TN-TunisTelephone: + 216 71 802 479www.mcm.com.tn

ZimbabweRepresentative office:UDDEHOLM Africa (Pty.) Ltd.P.O. Box 539ZA-1600 Isando/JohannesburgTelephone: +27 11 974 2781www.bohler-uddeholm.co.za

Other African CountriesASSAB INTERNATIONAL ABBox 42SE-171 11 Solna, SwedenTelephone: +46 8 564 616 70www.assab.se

www.assab.com www.uddeholm.com www.uddeholm.com

Network of excellenceUddeholm is present on every continent. This ensures you

high-quality Swedish tool steel and local support wherever you

are. Assab is our wholly-owned subsidiary and exclusive sales

channel, representing Uddeholm in various parts of the world.

Together we secure our position as the world’s leading supplier

of tooling materials.

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Uddeholm is the world’s leading supplier of tooling materials. This

is a position we have reached by improving our customers’ everyday

business. Long tradition combined with research and product develop-

ment equips Uddeholm to solve any tooling problem that may arise.

It is a challenging process, but the goal is clear – to be your number one

partner and tool steel provider.

Our presence on every continent guarantees you the same high quality

wherever you are. Assab is our wholly-owned subsidiary and exclusive

sales channel, representing Uddeholm in various parts of the world.

Together we secure our position as the world’s leading supplier of

tooling materials. We act worldwide, so there is always an Uddeholm

or Assab representative close at hand to give local advice and support.

For us it is all a matter of trust – in long-term partnerships as well as in

developing new products. Trust is something you earn, every day.

For more information, please visit www.uddeholm.com or www.assab.com