Technical Guide
Comparative Analysis of Metallic Materials Commonly Used in Industrial Blades
2026-02-03
Abstract
The performance and service life of industrial blades are largely determined by material selection. Different metallic materials provide varying combinations of hardness, wear resistance, toughness, and thermal stability. This article presents a structured comparison of widely used blade materials and includes typical mechanical and physical property data to support technical evaluation and selection.
1. Introduction
Industrial blades are used in a wide range of sectors, including metal processing, paper converting, plastic film slitting, and composite material cutting. Working conditions may involve continuous operation, elevated temperatures, abrasive materials, or impact loading. As a result, the choice of blade material directly affects cutting quality, maintenance intervals, and production costs.
Common metallic materials for industrial blades include carbon tool steel, alloy tool steel, high speed steel, tungsten carbide, and stainless tool steel. Each material offers a distinct balance between hardness and toughness, which influences wear resistance and resistance to chipping.
2. Overview of Key Material Properties
Table 1 summarizes the typical property ranges of the most common materials used in industrial blades. Values may vary depending on specific grade, heat treatment, and manufacturing process.
Table 1. Typical Mechanical and Physical Properties
| Material | Hardness | Tensile Strength (MPa) | Transverse Rupture Strength (MPa) | Max Working Temperature (°C) | Density (g/cm³) |
|---|---|---|---|---|---|
| Carbon Tool Steel | 55–62 HRC | 700–900 | 1,500–2,000 | ~200 | 7.8 |
| Alloy Tool Steel (D2 / SKD11) | 58–62 HRC | 900–1,200 | 2,000–2,500 | 250–300 | 7.7 |
| High Speed Steel (M2) | 60–65 HRC | 1,000–1,400 | 2,500–3,200 | ~550 | 8.1 |
| High Speed Steel (M42) | 64–67 HRC | 1,100–1,500 | 2,800–3,500 | ~600 | 8.2 |
| Tungsten Carbide (WC-Co) | 75–92 HRA | — | 1,800–3,000 | 800–1,000 | 14.0–15.0 |
| Stainless Tool Steel (440C) | 56–60 HRC | 760–1,000 | 1,900–2,200 | ~250 | 7.7 |
Note: Hardness of carbide is commonly measured on the HRA scale due to its extremely high hardness compared with steel.
3. Wear Resistance and Toughness Comparison
Wear resistance and toughness are two of the most important performance indicators for industrial blades. Harder materials generally provide better wear resistance but lower impact resistance.
Table 2. Relative Performance Comparison
| Material | Wear Resistance | Toughness | Edge Stability at High Speed | Regrindability |
|---|---|---|---|---|
| Carbon Tool Steel | Medium | High | Low | Good |
| Alloy Tool Steel | High | Medium | Medium | Good |
| High Speed Steel | Very High | High | High | Very Good |
| Tungsten Carbide | Excellent | Low to Medium | Very High | Limited |
| Stainless Tool Steel | Medium | Medium | Low to Medium | Good |
Tungsten carbide provides the highest wear resistance but is more sensitive to impact and vibration. High speed steel offers an excellent balance between wear resistance and toughness, making it suitable for high speed and intermittent cutting.
4. Thermal Performance
Cutting operations often generate significant heat, especially at high speeds. The ability of a material to maintain hardness at elevated temperature is critical.
Table 3. Thermal Stability Comparison
| Material | Temperature Where Hardness Begins to Drop Significantly |
|---|---|
| Carbon Tool Steel | Around 150–200 °C |
| Alloy Tool Steel | Around 200–300 °C |
| High Speed Steel (M2) | Around 500–550 °C |
| High Speed Steel (M42) | Around 550–600 °C |
| Tungsten Carbide | Above 800 °C |
| Stainless Tool Steel | Around 200–250 °C |
High speed steel and tungsten carbide are therefore preferred for high speed cutting where frictional heat is significant.
5. Application-Oriented Material Selection
Table 4. Recommended Materials by Application
| Application Condition | Recommended Material |
|---|---|
| Low speed cutting of paper, plastic, rubber | Carbon Tool Steel |
| General slitting of films, tapes, thin metal sheets | Alloy Tool Steel |
| High speed precision cutting | High Speed Steel |
| Abrasive materials or long continuous production | Tungsten Carbide |
| Humid, washdown, or food processing environments | Stainless Tool Steel |
6. Conclusion
Material selection for industrial blades requires balancing hardness, wear resistance, toughness, and thermal stability. Carbon tool steel remains a cost-effective solution for light duty applications. Alloy tool steel offers a balanced combination of performance and affordability for general industrial use. High speed steel is well suited to high temperature and high speed cutting conditions due to its superior red hardness and toughness. Tungsten carbide provides maximum wear resistance and long service life in demanding production environments. Stainless tool steel is selected primarily where corrosion resistance is required.
A careful evaluation of operating speed, cutting material, load conditions, and environmental exposure will ensure the most suitable material is chosen, leading to improved cutting performance and reduced downtime.