Bulk Analysis of High-Speed and Cold-Working Tool Steel

Importance of the Topic

Tool steels are critical in manufacturing due to their combined hardness, wear resistance, and toughness. Precise chemical composition directly influences performance under high temperatures, repeated impact, and abrasive environments. Reliable analysis of alloy content ensures cost control, quality assurance, and consistency in tool performance across sectors such as metal cutting, forming, and stamping.

Objectives and Overview of the Application Note

This note presents a protocol for bulk analysis of high-speed and cold-working tool steels using the LECO GDS900 glow discharge atomic emission spectrometer (GDS-AES). It describes how routine determination of iron, carbon, and key alloying elements (Cr, V, W, Mo) can classify tool steel grades, verify incoming materials, and support production and quality control in steel mills and tool manufacturers.

Methodology and Instrumentation

• Instrument: LECO GDS900 atomic emission spectrometer with a glow discharge source and CCD-based optics for stable, linear response across alloy concentrations.
• Sample Preparation: Surfaces prepared on 120-grit zirconium oxide belts or discs using a LECO BG grinder or PX polisher to ensure uniform sputtering.
• Calibration: Factory-installed curves covering low to high concentrations for Cr, Mo, V, and W. Working curves built from Certified Reference Materials (CRMs) and Reference Materials (RMs) from BAS, Brammer, and ARMI, supplemented by customer standards.
• Drift Control: Non-certified set-up standards (SUSs) used for drift correction; RMs/CRMs substituted when necessary.
• Analysis Times: Three consecutive analyses in 90 seconds with “analyze all in one spot” mode (start-up/presputter 60 s, each read 10 s).

Main Results and Discussion

Repeated measurements on five tool steel grades (A-11, D-2, M-2, T-1, M-1) demonstrate excellent accuracy (averages within 1% of certified values) and precision (RSD typically <1%). Key observations:

• Carbon and chromium measurements yielded RSDs below 0.5%, confirming robust quantification of major and minor constituents.
• Alloying elements such as vanadium and molybdenum displayed RSDs below 1%, even at high concentrations in high-speed grades.
• Trace elements (P, S, Cu, Ni) were reliably detected with RSDs under 1% for most grades, highlighting low spectral interference and linear detector response.

These results confirm the GDS900’s capability for rapid multi-element profiling, supporting tight process control and grade conformity checks.

Benefits and Practical Applications

• Fast throughput: Multiple analyses without repositioning minimize cycle time and increase productivity.
• Comprehensive alloy profiling: Simultaneous determination of major, minor, and trace elements supports precise grade identification.
• Quality assurance: Reliable data ensure incoming material verification and final product certification.
• Cost optimization: Accurate alloy control reduces over-alloying and material waste, cutting production costs.

Future Trends and Possibilities for Use

Advances in glow discharge technology and data analytics are driving further improvements in sensitivity, spectral resolution, and automation. Integration with digital manufacturing systems enables real-time quality monitoring and closed-loop control of alloying processes. Emerging applications include high-throughput screening of additive-manufactured metal powders and recycling streams, as well as expanded analysis of non-ferrous and composite materials.

Conclusion

The LECO GDS900 offers a robust, accurate, and efficient solution for bulk analysis of tool steels. Its linear response, low interference, and rapid analysis support production environments where consistent material performance is essential. Adopting this method enhances product quality, reduces costs, and streamlines alloy management in tool steel manufacturing and usage.