1. SFMSpray formed steelsThe next generation high-performance tooling materialLauri EklinSF Metals Ltd.

2. It is rare, that a new product enables as big cost savings and productivityimprovements as spray forming steels do for tooling materials.Even better, these improvements come with no cost of change. Usually, someproduction trials is enough for the supplier to fine tune the correct alloying andheat treatment.By switching to spray formed steels you can reduce your tooling or wearing partcosts by 50%, or more.SFM_____________________________Nykyn vain harvoin tulee vastaan tuote, joka mahdollistaa sellaiset sstt jatuottavuudenparannukset tykalu- ja kulutusosissa kuin spray forming -terkset.Nm edut voidaan hydynt varsin helposti ja ilman kalliita lisinvestointeja.Kytnnss tarvitaan vain muutama tuotantokoe asiakkaanprosessissa/laitteessa, jotta toimittaja voi hienost seostuksen jalmpksittelyn terkselle.Tykalu- ja kulutusosien kustannuksissa on mahdollista sst jopa 50% taienemmn. 3. SFMIntroduction Spray formed steels are superior materials compared to conventionallyproduced cold working, hot working and high speed steels Strength, hardness, thermal and wear resistance 4. SFMIntroduction Spray formed steels are superior materials compared to conventionallyproduced cold working, hot working and high speed steels Strength, hardness, thermal and wear resistance The most obvious application areas are: Forging, extrusion and die casting dies High wear toolings/components in mining and construction, metalsprocessing and other process industries Other tools/tooling manufacture 5. SFMIntroduction Spray formed steels are superior materials compared to conventionallyproduced cold working, hot working and high speed steels Strength, hardness, thermal and wear resistance The most obvious application areas are: Forging, extrusion and die casting dies High wear toolings/components in mining and construction, metalsprocessing and other process industries Other tools/tooling manufacture Lifetimes of componenta made from SF steels are usually double, or higher,compared to conventionally produced high grade steels 6. SFMIntroduction Spray formed steels are superior materials compared to conventionallyproduced cold working, hot working and high speed steels Strength, hardness, thermal and wear resistance The most obvious application areas are: Forging, extrusion and die casting dies High wear toolings/components in mining and construction, metalsprocessing and other process industries Other tools/tooling manufacture Lifetimes of componenta made from SF steels are usually double, or higher,compared to conventionally produced high grade steels In many applications SF steels perform equally to powder metallurgicallyproduced steels 7. SFMAdvantages of spray formed steelsTechnical/product benefitsBetter processing properties (e.g. machinability)Higher process / production up-time (when used as aprocess component, e.g. in materials handling, drilling, etc.)More competetive end-product (weight reduction,performance via durability, lower cost, etc).ProcurementcostsWhen replacing hard metal or powder metal part w/ SFsteel (200% to 400% cost saving)Weight reduction less material neededLifetime benefits(toolings)2 x forging dies, HPDC dies3 x cold extrusion ram, thread rolling die 8. SFMAdvantages of spray formed steelsTechnical/product benefitsBetter processing properties (e.g. machinability)Higher process / production up-time (when used as aprocess component, e.g. in materials handling, drilling, etc.)More competetive end-product (weight reduction,performance via durability, lower cost, etc).ProcurementcostsWhen replacing hard metal or powder metal part w/ SFsteel (200% to 400% cost saving)Weight reduction less material neededLifetime benefits(toolings)2 x forging dies, HPDC dies3 x cold extrusion ram, thread rolling dieOverall benefits -50% TCO and up to -80% TCO reported 9. SFMAdvantages of spray formed steelsTechnical/product benefitsBetter processing properties (e.g. machinability)Higher process / production up-time (when used as aprocess component, e.g. in materials handling, drilling, etc.)More competetive end-product (weight reduction,performance via durability, lower cost, etc).ProcurementcostsWhen replacing hard metal or powder metal part w/ SFsteel (200% to 400% cost saving)Weight reduction less material neededLifetime benefits(toolings)2 x forging dies, HPDC dies3 x cold extrusion ram, thread rolling dieOverall benefits -50% TCO and up to -80% TCO reportedAs a principle, if the anticipated benefits are notin the range of double lifetime or similarsignificant productivity improvement, SF Metalswill clearly communicate this to the customer.We believe strongly in win-win cases, only 10. SFMThe Spray forming process Melt is poured in an inertatmosphere and atomized in ahigh-speed gas flow (300 m/s) intodroplets the size of 10- 200 m 11. SFMThe Spray forming process Melt is poured in an inertatmosphere and atomized in ahigh-speed gas flow (300 m/s) intodroplets the size of 10- 200 m The droplets undergo rapidsolidification ( > 1,000 K/s), whichresults in an ultrafine grainstructure, minimum segregationand an excellent carbidemorphology 12. SFMThe Spray forming process Melt is poured in an inertatmosphere and atomized in ahigh-speed gas flow (300 m/s) intodroplets the size of 10- 200 m The droplets undergo rapidsolidification ( > 1,000 K/s), whichresults in an ultrafine grainstructure, minimum segregationand an excellent carbidemorphology Melt droplets are targeted tosolidify in the form of a billet. 13. SFMThe Spray forming process Melt is poured in an inertatmosphere and atomized in ahigh-speed gas flow (300 m/s) intodroplets the size of 10- 200 m The droplets undergo rapidsolidification ( > 1,000 K/s), whichresults in an ultrafine grainstructure, minimum segregationand an excellent carbidemorphology Melt droplets are targeted tosolidify in the form of a billet. The billet is subsequently forged 14. Examples of the physical properties of spray formed steelsM2 and M35 steels vs. SF steel of identicall compositionSFM 15. Examples of the physical properties of spray formed steelsM2 and M35 steels vs. SF steel of identicall compositionSFMTensile strength: +25%Impact strength: +50% ... +100% 16. SFMExample: D2 cold work steels D2 steel is a high-chromium tool steel. It is especially favored in applicationwhere high wear and abrasion resistance are needed. Typical applications for D2 Steel inclide stamping, forming, punching,shredding, cutting, toolings 17. H13 steel cast and annealed As spray formedSFMHot working steels example H13 H13 steels are hot working steels with high hardenability and both thermal andwear resistance Typical applications are pressure die casting tools, extrusion tools, forging dies,hot shear blades, stamping dies, plastic molds. ESR H13 is great for aluminumdie-casting tools and plastic mold tools requiring a very high polish. Spray formed steel of identical composition has a much finer andhomogeneous grain structure. Better properties in above-mentionedapplications. 18. .SFMApplicationsSpray forming is an innovative method for manufacturing high-alloyed steelsand other materialsSpray formed steels are superior compared to normal cold working, hot workingand high speed, and offer an extremely competetive cost to performance ratio.In many applications, such as forging dies.... 19. .SFMApplicationsSpray forming is an innovative method for manufacturing high-alloyed steelsand other materialsSpray formed steels are superior compared to normal cold working, hot workingand high speed, and offer an extremely competetive cost to performance ratio.In many applications, such as die and toolings for metal extrusion....Billet to be extruded Die(spray formed steel)Extruded product 20. .SFMApplicationsSpray forming is an innovative method for manufacturing high-alloyed steelsand other materialsSpray formed steels are superior compared to normal cold working, hot workingand high speed, and offer an extremely competetive cost to performance ratio.In many applications, such as die and toolings for metal extrusion....Billet to be extruded Die(spray formed steel)Extruded product 21. .SFMApplicationsSpray forming is an innovative method for manufacturing high-alloyed steelsand other materialsSpray formed steels are superior compared to normal cold working, hot workingand high speed, and offer an extremely competetive cost to performance ratio.In many applications, such as die and toolings for HPDC... 22. .SFMApplicationsSpray forming is an innovative method for manufacturing high-alloyed steelsand other materialsSpray formed steels are superior compared to normal cold working, hot workingand high speed, and offer an extremely competetive cost to performance ratio.In many applications, such as high-wear parts in construction and mining... 23. .SFMApplicationsSpray forming is an innovative method for manufacturing high-alloyed steelsand other materialsSpray formed steels are superior compared to normal cold working, hot workingand high speed, and offer an extremely competetive cost to performance ratio.In many applications, such as cutting, toolmaking, etc.... 24. .SFMApplications... applications, such asForging diesMetal extrusionHigh pressure die castingHigh-wear parts in construction and miningCutting; ToolmakingToolings made of spray formed steel offer typically a double lifetime comparedto conventionally produced steels of equal chemical composition 25. .SFMApplications... applications, such asForging diesMetal extrusionHigh pressure die castingHigh-wear parts in construction and miningCutting; ToolmakingToolings made of spray formed steel offer typically a double lifetime comparedto conventionally produced steels of equal chemical composition 26. SFMProcess steps of different steel production methodsPowder Metallurgy Electroslag Remelting(ESR) Spray FormingMelting Melting MeltingAtomization Casting of electrodes SprayingClassification of powders Preparation of electrodes Forging, rollingMixing of powders Remelting Heat TreatmentCapsulation Diffusion annealing MachiningHot Isostatic Pressing Forging, rollingForging, rolling Heat TreatmentDecapsulation MachiningHeat TreatmentMachining 27. SFMProcess steps of different steel production methodsPowder Metallurgy Electroslag Remelting(ESR) Spray FormingMelting Melting MeltingAtomization Casting of electrodes SprayingClassification of powders Preparation of electrodes Forging, rollingMixing of powders Remelting Heat TreatmentCapsulation Diffusion annealing MachiningHot Isostatic Pressing Forging, rollingForging, rolling Heat TreatmentDecapsulation MachiningHeat TreatmentMachining 28. SFMProcess steps of different steel production methodsPowder Metallurgy Electroslag Remelting(ESR) Spray FormingClassification of powders Preparation of electrodesMixing of powders RemeltingCapsulation Diffusion annealingHot Isostatic PressingDecapsulation 29. SFMProcess steps of different steel production methodsPowder Metallurgy Electroslag Remelting(ESR) Spray FormingThanks to the short andeconomical productionprocess, the cost performanceratio of spray formed steels isas good as it is!Classification of powders Preparation of electrodesMixing of powders RemeltingCapsulation Diffusion annealingHot Isostatic PressingDecapsulation 30. Spray formed steel SFM2131 developed by SF Metals has provided its FortuneGlobal 500 customer in automotive industry with 50% lower toolings costs in forging,compared to high grade ESR hot work steels used by the customer earlier.SFMA case example of SF steels 31. The chief metallurgist of SF Metals, Dr. Y. YANG, inventor of the Precision SprayForming (PSF) rapid tooling and manufacturing technology, has been recognizedby the Chinese Society of Automotive Engineers with a "First Prize of ChinaAutomotive Industry Science and Technology Award 2013". This is for the firstcommercial trial in the world with PSF concept, which was performed with thespray formed steel grade SFM2131 at Dongfeng Motor Corporation, a FortuneGlobal 500 company.SFM 32. The chief metallurgist of SF Metals, Dr. Y. YANG, inventor of the Precision SprayForming (PSF) rapid tooling and manufacturing technology, has been recognizedby the Chinese Society of Automotive Engineers with a "First Prize of ChinaAutomotive Industry Science and Technology Award 2013". This is for the firstcommercial trial in the world with PSF concept, which was performed with thespray formed steel grade SFM2131 at Dongfeng Motor Corporation, a FortuneGlobal 500 company.SFM 33. SFMSF Metals SF Metals employs about 10 highly-skilled people engaged in running theplant, R&D, engineering and sales SF Metals has a network of about 30 selected manufacturing partnersranging from steel making to machine building, tooling, heat treatment,machining and metal processing techniques such as forging, rolling andextrusion, which enables SFM to flexibly use best available technologies foreach customer order and product. SFM is located in Foshan, the most developed area in China with strongindustrial infrastructures. It is just in the neighborhood of Hong Kong, aconvenient international logistics hub. In addition to operation in China, SF Metals has customer service andtechnical support in FinlandPrice is what you pay. Value is what you get Warren Buffet (and we agree!)