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That’s the theory, and the way we accomplish it is to cut (or roll) the ramp (thread) into the two pieces, male and female.  Hence, the tap and die.  A tap puts internal threads in a hole (like a nut).  A die puts external threads on a shaft (like a bolt).

In addition to the deviations of shaft and hub, the span, clearance or interference of the fit is shown as result. The tolerances according ISO 286 are defined ...

If you’re not that familiar of skilled with tapping, the best advice I can give is go slow.  Take your time and figure it out.  Test a bit with scraps of material that don’t matter.  You’ll get the hang of it pretty fast, because it’s not that complicated (from a high level view).  I’m not trying to minimize because there are a lot of details (like we covered above), but overall the concept is easy.  Try it a bit, and you’ll learn quick.

Tungsten steelvs stainlesssteel

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There is a lot written and a lot on video about thread tapping, so I’ll skip the details.  However, I will review just a couple things that help to get it right.

What istungsten steelused for

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One of the things I dislike most about tapping threads is the repetitive and time consuming nature of it.  Twist down, then back it just a little to break the chips, then twist down again.  Over and over for as many threads as you need.  If you need to go deep in a blind hole, then every once in a while you should back it out (mostly), blow the chips away, then twist it down to continue cutting.  For fine thread bolts, that can be a lot of twisting over and over.  If I have to do several, it’s just annoying.

The tungsten series include the T1 to T15 class alloys. Tungsten is a good carbide former that prevents grain growth, enhances toughness and increases red hardness and high temperature strength. Tungsten is used in hot forming tool steels and high-speed steels.

It is important to note that with aluminum this is less risky, but with steel, depending on the alloy, the forces internal to the tap can be really high.  With Steel and with other materials, especially when tapping is deep, be super careful with this technique, and use a lot of oil, because it’s a big hassle to dig out a broken tap.

That’s about it.  There is a ton of additional information about the tapping tools and about tapping in different metals.  Just search on-line and you’ll find as much detail as you want.  To me, it’s fascinating to look at the different cutting and tooth geometry for various metals, and the many different cutting fluids available.  Those are probably important for production environments, but for us in DIY, a good General Purpose tap with some sort of oil seems to work well enough for just about everything.

The American Iron and Steel Institute (AISI) has classified high-speed tool steels into about 40 individual categories. This classification system uses a T for referring to steels in which tungsten the primary alloying element. The letter T is followed by a number which distinguishes each of the tungsten tool steels ranging between T1 and T15.

Sometimes, doing it all by hand (without the drill press), the tap will go in slightly angled, and that messes up the start of the hole.  That is more true when using bottoming taps.  Lots of care in the start is really important.

aGroup W contains 0.025 max S, 0.20 max Cu and 0.025 max P. Other steels except group W contain 0.03 max S, 0.25 max Cu and 0.03 max P. Where specified, sulfur may be increased to 06 to 0.15% in order to improve machinability of group A, D, H, M, and T steels.

For this article, we’ll focus on the tap for cutting internal threads.  These are far more common for DIY simply because we can so easily buy the external threads in the form of a bolt.  Yes, we can also buy nuts (internal thread), but we sometimes need those internal threads in the part rather than adding a nut.  That’s where the tap comes in.

Tungsten Steelprice

If you’ve ever cross threaded a nut, then you know the issues if you don’t start the thread in straight.  That is exaggerated with a tap (and even more so with a die).  If you don’t get the tool straight with the hole to begin, it can make a bit of a mess.  That said, taps can be fairly forgiving and follow the hole if you’re careful.

Tap tool ends can be different based on what you’re trying to do.  Here are a few below.  The more threads that in the chamfer, the easier it is to get the tap to start straight, but the deeper you have to tap to get the same number of full threads.  The “Plug Chamfer” is the most common.  (Images from McMaster.com – best website ever.)

The most significant alloying elements found in tungsten high-speed steels include carbon, tungsten, cobalt, chromium and vanadium. Tungsten high-speed steels contain 4% chromium. T4 and T15 are the cobalt-base tungsten varieties that contain different amounts of cobalt. The T1 type of tungsten high-speed steels is free of cobalt or molybdenum.

Tungsten and steelalloy

Manufacturing facilities have complex machinery to put threads in parts with ease.  They have things set perpendicular to run perfectly — usually with dedicated machinery.  For DIY we don’t have that convenience nearly as much.  We need to rely more on our own setup and skill.

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Finally, what if the tap binds in the hole?  This can happen if the chips get too bungled up, or if the tap is at a slight angle.  If the tap gets stuck, treat it carefully because you definitely don’t want to break it.  I find the best thing is to twist in back and forth.  Start with light pressure, and apply more and more each time.  Turn left, then right, then left again and again.  Put a little oil down the hole too.  For me, the taps have always, eventually, come loose so I can back it out.

Tungsten steelcomposition percentage

Tungsten steelcomposition

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Invention of the thread has to be one of the greatest accomplishments.  Conceptually, it’s just a ramp wrapped around a rod that allows you to slide another ramp (equal and opposite) wrapped inside a hole until something causes them to stop — namely, the bolt gets tight.  With one inside the other, the continuous ramps are in contact with angles that keep them from sliding back.  That is, while under load the friction overcomes the sliding forces.  (Until, of course, other forces are present — like vibration, or you turning it with a wrench.)

Good luck with all your tapping.  Next up . . . read about what we consider the most important tools to have in the shop.

The aluminum extrusion is not the important part, it’s using the drill press to do the thread tapping.  Note that while the spindle is turning continuously, there is no chip breaking.  After the spindle stops, we need to do the chip breaking to avoid getting the tap stuck.

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Tungsten steelvstungstencarbide

There are several versions of taps available.  Just a quick look online will show straight taps, spiral taps, bottom taps and chip clearing taps (just to name a few).  There are a lot of specialty tools, and specialty options, so don’t worry too much about all the details.

High-speed steels are tool steels that find applications in machine tools that have high rates of material removal. Tungsten high-speed steels (group T) and molybdenum high-speed steels (group M) are two types of high-speed steels. These two groups of high-speed steels have similar hardening abilities and other characteristics.

Conceptually, threading a hole is easy.  Just drill the right size hole, then put the tap end in the hole and start twisting.  But what if the tap does not enter the hole straight?  What if you need to tap a hole right to the bottom?  What if the tap binds in the hole?

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High-speed tool steels are capable of being hardened to 62 - 67 HRC and their hardness can be maintained at service temperatures up to 540°C (1004°F). This makes them suitable for use in high-speed machinery.

Tungsten and steelproperties

The video shows a simple way to align things when thread tapping.  Using the same set-up as when you drill the hole, leverage the location and vertical position of the drill press to hold the tap straight.

A Tap and Die set is a near must for a DIY fab shop.  While the thread creating functions are pretty easy to visualize, sometimes getting the tread to start straight and run true is a different matter. The thread tapping functions are easiest, so let’s talk about that first.  Dies are are less frequent, and tend to be more difficult to start perfectly straight.  Since that’s really another topic, if you’re interested, there’s this article about Successful Threads With A Die.  In the meantime, let’s get back to internal thread tapping.

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White and Taylor developed the type T1 series of tungsten high-speed steels. In the early 1900s, they discovered that certain steels exhibited red hardness and such steels comprised more than 14% W, about 0.3% V and about 4% Cr. T1 in its earliest form contained about 18% W, 0.68% C, 0.3% V and 4% Cr. An increase in the quantity of vanadium was seen by 1920. The carbon content of most steels also increased to approximately 0.75% over the years.

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Tungsten high-speed steels have good wear resistance and high red hardness. The maximum hardness of group T steels differs according to the carbon content and also the alloy content. A minimum hardness of 64.5 HRC can be imparted to all types of high-speed steels. Types such as T15 can be hardened to 67 HRC as they have high carbide and carbon content (1.55%). Hence T15 is considered as the most wear-resistant steel of the tungsten high-speed steel series. Tungsten high-speed steels comprising more than 1.0% C and 1.5% V produce a high number of wear-resistant hard carbides in the microstructure due to the presence of high carbon and alloy content. Tungsten high-speed steels are deep hardening when they are quenched from their hardening temperature of 1205 to 1300°C (2200 to 2375°F). Solid tools such as cold extrusion punches and broaches with large diameters are made from tungsten high-speed steels. Full hardness is provided for tools with large diameters using an accelerated oil quench.

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So, what about using machinery to assist?  Sure, that works too.  But, do it really carefully.  Here’s a quick video of thread tapping into the ends of some aluminum extrusions.  The component not shown in the video is the vise attached to the press table, hanging over the edge of the table to allow drilling into the end of the long work-piece.  (Sorry, I should have shown that.)