integraTool procedure

integraTool technical procedure is an HTS established process for the production and certification of die components, based on the integration of steel supply, rough machining, heat treatment, and final inspection, into a single, rigorously controlled workflow.

integraTool technical procedure overview

By managing the entire process from material selection to post-treatment verification, we ensure that both material and mechanical properties meet the required specifications. This approach eliminates the risk of discrepancies between the steel supplier and the heat treatment contractor, providing a consistent and repetitively reliable outcome.

The integraTool procedure also includes comprehensive documentation, from steel mill certificates to heat treatment diagrams and 3D scan report to verify compliance with quality standards and to guarantee that the final product is ready for machining.

Simplifying complexity

 Typical die component procurement process
 integraTool die component procurement process

We integrate premium hot work tool steel supply, machining before heat treatment, and heat treatment. By combining these services, we ensure exceptional quality control throughout the manufacturing process. We provide extensive quality control certificates and guarantee the mechanical properties after heat treatment.
Our expertise includes tooling for die casting, plastic injection molding, and forging. integraTool services enhance efficiency, quality, and supply chain optimization with 
customized approaches tailored to meet your specific needs.

integratool benefits

PREMIUM HOT WORK TOOL STEEL

For integraTool, we use premium hot work tool steels produced by SIJ Metal Ravne. To ensure the quality of steel, the steel supplier, must comply to integraTool standards when it comes to melt practice, chemical composition, forging, hardness, microcleanliness, ultrasound inspection, impact capability testing, grain size, annealed microstructure and banding segregation.

After the steel is tested and delivered by the steel mill, HTS Laboratory performs an additional series of tests, to verify that the steel adheres to integraTool requirements. The frequency of testing is 100% (each steel block is tested, without exception)

integraTool defined steel requirements
SITHERM 2343R
TOUGHNESS NADCA#207-2016: KV2 (J)    
class 1 avg.≥ 23 J min. ≥ 18 J
class 2  avg.≥ 23 J  min. ≥ 17 J
MICROSTRUCTURE NADCA#229: 2016    
class 1  AS1-AS6  
class 2  AS1-AS9  
GRAIN SIZE ASTM E112    
class 1 ≥ 7  
class 2 ≥ 6  

 *class 1 < 810 x 365, class 2< 1010x450

SITHERM S353R

SITHERM S353R is a premium hot work tool steel grade with improved toughness, better resistance to heat cracking, wear and plastic deformation. It is used in hot-work applications like die casting, die forging and extrusion. 

TOUGHNESS NADCA#207-2016: KV2 (J)    
class 1 avg.≥ 25 J min. ≥ 20 J
class 2  avg.≥ 23 J min. ≥ 18 J
MICROSTRUCTURE NADCA#229: 2016    
class 1  AS1-AS6  
class 2 AS1-AS6  
GRAIN SIZE ASTM E112    
class 1 ≥ 7  
class 2 ≥ 7  

*class 1 < 810 x 305, class 2 > 810 x 305

 

Learn more about SITHERM S353R 

HIGH PRECISION MACHINING

Compliance with integraTool requirements is ensured throughout the order process, machining requirements, and machining process.

integraTool machining process:

  • ABC milling
  • Cooling channels drilling, threads. Ends of channels are rounded.
  • Holes for cores and ejectors with offset are machined
  • Non-tolerance holes with finish are machined
  • 3D surface is machined with predefined offset:
    General offset:
    dimension < 400 x 400 = 1.0 mm/wall
    dimension < 600 x 600 = 1.5 mm/wall
    dimension > 600 x 600 = 2.0 mm/wall

    *Offset is defined after 3D documentation is received
    **Smallest milling tool for 3D shape Ø10 R5

ADVANCED HEAT TREATMENT

integraTool procedure strictly defines the heat treatment procedure in the areas of equipment, furnace loading, thermocouple placement, stress relieving, preheating, austenitizing, quenching and tempering. 

Based on stringent procedure we guarantee the minimum toughness for die components produced according to integraTool procedure

  • SITHERM2343R, min 14J
  • SITHERM S353R, min 16J

STRINGENT QUALITY CONTROL

We provide comprehensive certificates that detail our rigorous testing and validation processes. Our documentation includes detailed microstructure analyses conducted both before and after heat treatment. We also provide heat treatment curves and mechanical properties certificates that encompass comprehensive data on hardness and toughness. These rigorous testing and validation processes ensure that our components meet the highest standards of durability, reliability, and performance.

Quality control procedures and documentation include: 

  • Material certificate
  • Microstructure before and after heat treatment
  • Heat treatment certificates
  • 3D scan
  • Quality control documentation bundle

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