When standard tool steel specifications don’t meet your project requirements, selecting the right supplier is critical. You may need custom chemical compositions, unusual dimensions, or special heat treatments—requirements that fall outside catalog options. FCS Steel has the technical knowledge, production capability, and quality control to handle these non-standard tool steel orders reliably.
This guide outlines how FCS Steel manages custom tool steel requests from start to finish, including chemical adjustments, size and shape modifications, specialized heat treatments, and rigorous quality assurance.
What Are Non-Standard Tool Steel Orders
Non-standard tool steel orders exceed typical catalog specifications. They require precise modifications in one or more of the following areas:
Dimensions – thickness, width, length, or complex shapes
Chemical composition – custom alloy adjustments for wear resistance, toughness, or heat performance
Heat treatment – specialized tempering, cryogenic treatment, or surface hardening
Mechanical properties – hardness, strength, and distortion control
Differences from Standard Orders
Standard orders come from pre-stocked grades and dimensions, with delivery in days to weeks. Non-standard orders involve:
Longer lead times: 15–60% longer depending on complexity
Higher minimum order quantities: 300–800 kg versus standard 100 kg
Premium pricing: 15–40% above catalog rates for processing, testing, and custom setups
Stricter technical requirements: detailed drawings, spec sheets, and quality documentation
Common Customization Types
- Dimensional Adjustments – Example: a precision mold requiring 2.5 mm thickness instead of standard 3 mm
- Chemical Composition Changes – Example: aerospace parts needing extra vanadium to improve high-temperature wear resistance
- Heat Treatment Modifications – Example: deep cryogenic treatment to extend tool life
- Combined Specifications – Example: automotive stamping dies requiring non-standard size, modified chromium levels, and nitrided surfaces
FCS Steel’s Non-Standard Order Capabilities
FCS Steel integrates multiple advanced metallurgical and production technologies:
12-ton LF (Ladle Furnace) alloy adjustment system for precise chemical control
6 ESR (Electroslag Remelting) lines for high purity and reduced sulfide/oxide content
VD (Vacuum Degassing) system for ultra-low hydrogen and nitrogen levels
Forging, machining, and heat treatment systems with strict tolerances
These capabilities allow the production of steels with custom chemistry, size, and hardness, while meeting tight quality and delivery requirements.
Custom Chemical Composition Adjustments
LF Ladle Furnace Precision
Carbon control: ±0.02%
Chromium, molybdenum, vanadium: ±0.3%
Sequence-controlled alloy additions ensure each element is added at the ideal temperature and mixed thoroughly.
Example: A Swiss cutting tool order requiring 0.92% carbon and 4.8% chromium was achieved exactly across a 3,200 kg batch, saving remelting costs.
VD Vacuum Degassing
Removes hydrogen (<1.5 ppm) and nitrogen (<50 ppm)
Prevents internal cracks and surface defects during hardening
Ideal for aerospace and medical tooling requiring ultra-clean steel
Example: VD-treated batches reduced surface defects by 60–75% compared to non-degassed steel
ESR Electroslag Remelting
Slag temperature: 1,900–2,000°C
Oxide removal: 85–92%
Sulfide content: reduced from 0.008% to 0.0021%
Example: European bearing dies requiring max sulfur 0.0025% were delivered below 0.0022%
Impact on Lead Time and Cost: Custom chemical adjustments add 8–12 days and cost 12–30% more, depending on single- or multi-element changes.
Special Size and Shape Requirements
Forging and Machining
10-ton forging hammer handles bars 25–450 mm diameter and flat stock up to 380 mm thick
Complex shapes require multiple passes with intermediate annealing
Machining tolerances: ±0.15 mm (turning), ±0.08 mm (milling), ±0.03 mm (centerless grinding)
Example: A Korean mold maker required 78 mm bars with ±0.05 mm tolerance. Using a three-step process, FCS Steel delivered all 40 pieces within spec.
Oversized and Undersized Solutions
Large bars (>450 mm diameter) are forged in segments and welded under controlled heat, followed by stress-relieving heat treatment
Thin profiles (<15 mm) require hardened dies to prevent warping
Example: Mining crusher die, 620 mm diameter, delivered successfully from three forged sections.
Customized Heat Treatment
Preheating and Quenching
Preheat: 1-hour per inch thickness to prevent thermal shock
Quenching media options: salt bath, oil, polymer, air, nitrogen gas
Example: Belgian punch requiring 1.2510 steel at 58 HRC was quenched in an interrupted salt bath and achieved 58.3 HRC uniformly
Hardness and Tempering
Special hardness requirements (≥57 HRC or ≤225 HBS) achievable with controlled quenching and multiple tempering cycles
1–3 tempering cycles at 150–650°C depending on steel grade and application
Vacuum and controlled-atmosphere furnaces reduce distortion by up to 90%
Example: Swiss precision die project achieved ±0.05 mm tolerance after vacuum hardening, average deviation 0.04 mm.
Quality Assurance for Non-Standard Orders
- Raw Material Inspection – Spectrometer tests and magnetic particle inspection
- Melt Expert Software – Real-time chemistry monitoring every 90 seconds
- Mechanical Testing – Tensile strength ≥672 MPa, yield ≥472 MPa
- Traceability – Unique heat numbers link all production and test records
- Non-conformance Handling – Immediate batch hold and root cause analysis; non-standard orders are never reworked if out of spec
Example: Mexican automotive client avoided $18,000 in processing losses due to early defect detection.
Order Process and Lead Time
- Technical Evaluation – Feasibility check, drawing review, tolerance assessment
- Quotation and Agreement – Transparent cost breakdown and lead time estimate
- Production Scheduling – ERP-tracked progress with weekly updates
- Delivery – Standard customizations: 25–35 days; complex orders: 45–60 days
- Rush Orders – Expedited for moderate customizations, 35–50% premium, limited capacity
Example: South Korean client received 850 kg of modified D2 steel in 16 days using prioritized furnace scheduling and overtime machining.
Pricing Structure
Chemical composition adjustments: +12–25%
Special heat treatment: +20–35% (up to 55% for multi-step processes)
Dimensional customization: +15–30%
Volume discounts: 1,000–2,999 kg: 8–12%; 3,000–7,999 kg: 15–22%; ≥8,000 kg: 25–30%
Example: German client ordered 30 tons modified H13 at ¥68/kg; volume discount reduced it to ¥56.44/kg, saving ¥62,424.
Technical Support and Consultation
Pre-sales advisory: Material selection, feasibility analysis, cost-performance evaluation
Engineering team: 5 metallurgical engineers (8–15 years experience), 2 ASM-certified heat treatment experts, 3 mechanical engineers with automotive/aerospace backgrounds
Engineers remain assigned throughout project to prevent tolerance or surface finish issues
Example: Furniture hardware maker switched from O1 to A2 steel; punch life increased from 45,000 to 82,000 hits, net savings ¥31,000 over six months.
Conclusion
FCS Steel leverages decades of hands-on metallurgical and production experience to handle non-standard tool steel orders with precision. From custom chemical compositions to special sizes and heat treatments, the company combines LF refining, VD vacuum degassing, ESR remelting, forging, and machining capabilities with rigorous quality checks. Every project is supported by experienced engineers who ensure feasibility, tight tolerances, and predictable lead times. For demanding aerospace, automotive, and precision tooling applications, FCS Steel turns challenging specifications into reliable, high-performance solutions.