Influence of Powder Type and Density on Pore Closure and Surface Hardness Changes Resulting from Steam Treatment of Sintered Iron

Abstract

Two types of Höganäs iron powder – sponge, and atomized with very high compressibility (ASC), after compaction to densities of 6·0, 6·4, and 6·8 Mg m^?3 and sintering under standard conditions were subjected to steam oxidation at 450, 525, and 600°C. The progress of oxidation was studied by measurement of weight gain and hardness. X-ray methods were used to determine the type of oxide present after treatment. During steam oxidation the type of powder has an important influence on the extent of pore closure and on the morphology of the oxide produced. The kinetics of oxidation were always faster for sponge iron than for atomized iron and there was a corresponding increase in the rate of pore closure and in surface hardness. For effective sealing of surface pores components should be of high density and be steam treated at 600°C but for attainment of maximum hardness components should be of low density and be steam treated at 525°C.     

Relationship between Mechanical Properties and Nature of Fracture Surface of Powder Steels under High-Temperature Tension

Metallurgist - Results of research on high-temperature tension for powder steels by the Swedish company Höganäs are analyzed. Morphological differences in the structure through the...     

Effects of Aging and Steam Oxidation on Sintered Irons and Steels Containing Phosphorus

Abstract

Dramatic reduction of ejection forces in a metal powder compaction process has been achieved using a balanced die method. The approach uses a toolset consisting of a thin walled die in a fairly rigid metal, with a rubber sleeve capable of transmitting high radial pressure. By maintaining a pressure balance between internal compaction pressure and external ‘bolstering’ pressure across the thin wall die, the ejection forces were reduced to almost zero. With limited equipment available, the compaction process was carried out in incremental stages to produce cylindrical metal billets of 32 mm diameter by 20 mm height. Green densities of 6·49 Mg m^?3 were achieved for NC100 iron powder supplied by Höganäs at much lower compaction pressure than those reported elsewhere. PM/0711     

LUBRICATION EFFECTS IN THE COMPACTION OF SPONGE-IRON POWDER AT LOW AND HIGH SPEEDS

Abstract

The effects of the amount and method of lubrication have been investigated when compacting Höganäs sponge-iron powder, NC100-24, at both low and high speeds. Pressing characteristics, ejection loads, and the final properties of the sintered compacts were markedly affected by both the amount and the method of lubrication. From the results obtained, an optimum amount of admixed zinc stearate is recommended for both low and high-speed conditions.     

Characteristic of interconnected porosity in ferrous PM compacts

Abstract

The purpose of this work was to quantitatively describe the interconnected porosity in iron compacts, both in macro- and microscale. Size and volume fraction of micro-, meso- and macropores were examined in the compacts with density within 5˙6–6˙4 g cm^?3, made in laboratory conditions of two iron powders: NC100˙24 and ASC100˙29 manufactured by Höganäs Company. The interconnected porosity was determined using the method based on measuring the sorption isotherms of CO₂ and benzene at T=25°C in static conditions in a high vacuum gravimetric appliance equipped with McBain–Bakr weighers.

Volume distributions of individual size classes of micro- and mesopores in the compacts made of both iron powders with fixed density were compared.

Relationships between density and the interconnected micro- and macroporosity of the examined compacts were determined.     

Warm powder compaction substitutes conventionally double pressed and double sintered synchroniser hubs

Abstract

Within a project supported by the European Union a consortium consisting of the companies Fraunhofer Institute for Structural Durability LBF, AMES, Miba, GKN, Federal Mogul, Höganäs, RWTH Aachen, Peugeot/Citroën and Fiat worked on the realisation of heavyduty gearbox components by warm powder compaction technology. In this paper, part of this work will be reported, namely the manufacturing of synchroniser hubs by this new technology. Until now these hubs were manufactured by the double pressing and double sintering route.

Based on service load measurements in a gearbox of a Peugeot 506, vehicle fatigue tests were carried out with conventionally and warm pressed hubs. The results of fatigue tests with hubs as well as the durability tests carried out in the gearboxes of Peugeot/Fiat revealed the same performance for both technologies. As a consequence, the hubs produced by warm powder compaction can substitute for the ones produced conventionally. Further, the new technology reveals economic advantages with regard to the powder price as well as production costs.     

高密度铁基粉末冶金零件制备技术

介绍了东睦新材料集团股份有限公司已经使用的高密度铁基粉末冶金产品制造技术,包括温压成形、温模压制、复压复烧等,并讨论了这些技术的优缺点。所述高密度铁基粉末冶金零件制备技术虽可以提升粉末冶金零件的密度,强度也达到较高的水平,但是零件的精度及粗糙度等尚不能满足高端应用的要求,仍需进一步机加工。未来仍需提升粉末冶金模具的制造精度、粉末特性和工艺稳定性,开发低成本、高精度、高强度的烧结铁基零件制备技术。     

Numerical simulation of metal powder die compaction with special consideration of cracking

Abstract

Powder die compaction is modelled using the finite element method and a phenomenological material model. The Drucker–Prager cap model is modified with the goal to describe the formation of cracks during powder transfer, compaction, unloading, and ejection of the parts from the die. This is achieved by considering the cohesive strength and the cohesion slope, which characterise the current strength of the powder compact in the Drucker–Prager model, as state dependent variables. Evolution equations are formulated for these variables, so that the strength increases by densification and decreases by forced shear deformation. Some of the parameters appearing in the evolution equations are determined from measured green strength values. An iron based powder (Distaloy AE) is used for the experiments. Examples are shown to demonstrate that the density distribution can be calculated accurately as compared with an experiment, that cracking can be modelled at least qualitatively correctly, and that the compaction of complex 3D parts can be simulated.     

Effect of boron on microstructure and mechanical properties of PM sintered and nitrided steels

Abstract

PM Distaloy and Astaloy alloys have many applications in the automotive industry and are used in structural elements with different wear resistance values. Their main features are adequate density, hardness, tensile strength, and good ductility. For the purpose of the experiment presented here, Distaloy SA and Astaloy Mo powders, alloyed with various amounts of elemental boron powder, were used. The Distaloy and Astaloy alloys were produced through mixing, compacting, and sintering at t=1393 and 1473 K, and, after the completed sintering process, they were plasma nitrided at 793 K. Experimental results showed that if boron was added, while sintering, the shrinkage phenomena increased ( 1473 K) and some parameters of those alloys (density, hardness, and tensile strength) were improved. Upon the ion nitriding treatment of the surface of base Astaloy Mo samples, a surface layer was created composed of the ε solution and γ' nitride, whereas the surface layer on the Distaloy SA base was mainly composed of a γ' compound. Boron activates the sintering process of Distaloy SA and Astaloy Mo samples but it has no significant impact on the surface layer's thickness of Distaloy SA alloys as opposed to Astaloy Mo alloys in which boron promotes a greater thickness of surface layers along with a reduced depth of nitrogen diffusion.     

利用转炉烟尘铁粒制造粉末冶金用铁粉

转炉在吹炼过程中形成的铁粒，经过表面除杂和表面粗糙化处理后，其化学成分和粉末工艺性能符合粉末冶金用铁粉的要求。研究发现，铁粉松装密度由原始的3.82g/cm^3可降低到2.72g/cm^3。当铁粉松装密度为2.72g/cm^3时，粉末流速为29.3s/50g。该粉末在压力为420MPa的条件下压制，压坯密度达6.68g/cm^3，压坯强度高达12.68MPa，比具有相近松装密度的还原铁粉在相同压制条件制的压坯强度提高40％。铁粉的应用试验结果表明，该铁粉的压制和烧结性能良好。改性后的转炉烟尘铁粉可作为粉末冶金用铁粉新的制造原料。     

THE INFLUENCE OF POROSITY AND CARBON CONTENT ON THE FRACTURE TOUGHNESS OF SOME SINTERED STEELS

Abstract

Fracture toughness (K_IC) and mechanical properties at room temperature (RT) and at 200 K were evaluated for a range of sintered steels. In a series of quenched and tempered samples prepared from a lowalloy, atomized powder (Höganäs ATST-A) with 0·45 wt.-%C and density varying between 6·7 and 7·8 g/cm³ (powder forged), the K_IC varied between 28 and 80 MN/m^3/2 at RT and between 34 and 58 MN/m^3/2 at 200 K. There was a correlation between the K_IC and the yield strength of the porous materials, due to the fact that fracture of the specimen is effected by plastic instability on a micro scale. Adding carbon (0–0·84%C) and copper (2%) to a sponge-iron powder and sintering to a final density of 6·8 g/cm³ gave a material with a fracture toughness of ～34 MN/m^3/2 when the C content was >0·6%. At lower C contents the toughness was considerably increased, but it was not possible to obtain a valid. K_IC determination. In this investigation a new type of fracture-toughness specimen was used, the RCT specimen, diameter 75 mm and thickness 29 mm; by using this type as opposed to the ordinary CT variant, specimens ～50% larger could be used.     

Measurement of green strength of warm pressed Distaloy PM compacts: influence of specimen geometry and test method

Abstract

It is important that the green strength properties of powder compacts be accurately determined if advanced manufacturing techniques, such as green machining, are to be exploited successfully. In this study, the green strength of Distaloy AE Densmix, a powder mix designed for such applications, was measured using several test methods. Fracture statistics were correlated with compact density and test method employed, and the Weibull modulus calculated for each case. It was found that Weibull analysis accurately predicted the green strength dependence on the test configuration utilised.     

预混合粉末的研制

预混合粉末在防止化学成分偏析、提高混合粉流动性、改善生产现场环境方面有着明显的优势。其生产的零件相对于一般混合粉具有化学成分均匀、尺寸变化稳定、尺寸精度高和力学性能稳定的特点。本文针对Fe 1.0 %C 0 .7%Zn st预混合粉的生产工艺和粉末中石墨粉的被粘接情况进行了研究。研究结果表明 ,采用本工艺制造的预混合粉 ,与一般混合粉相比 ,在松装密度、压缩性相当的情况下 ,其流动性远远好于一般混合粉 ,而且其中的石墨颗粒能够被有效的粘接到铁颗粒表面上 ,从而达到防止偏析的目的     

Der Einfluß der Prüfmaschinenhärte auf die Ergebnisse des Zugversuchs

Erläuterung des Begriffs Maschinenhärte. Einfluß der Federkonstante der Prüfmaschine auf die Verlängerungsgeschwindigkeit von Zugproben in den einzelnen Abschnitten des Zugversuchs und deren Bedeutung bei der Ermittlung der unteren Streckgrenze und der Höchstkraft. Instabilitätspunkt und Tangentenbedingung. Ergebnisse von Zugversuchen mit Prüfmaschinen unterschiedlicher Härte. Verlauf von Dehnung und Einschnürung nach Überschreiten der Höchstkraft in Abhängigkeit von der Maschinenhärte. Sonderfälle des Kraft-Verlängerung-Schaubildes, Prüfmaschine mit geschlossenem Regelkreis. Einfluß der Probenabmessungen auf den Instabilitätspunkt.     

Effect of particle composition on consolidation of hot briquetted iron

Abstract

The influence of the carbon concentration of directly reduced iron (DRI) powders on the compressibility and fracture strength of hot briquetted iron (HBI) has been studied. Industrially produced DRI, pure iron powder and Fe–C alloy powders (synthetic DRI) were used in the study. It was found that the mechanism of compaction could be attributed to pure yielding. The pressure required to attain a given density increased proportionally with the carbon content. The morphology and phases present in DRI powder had a significant influence on the compressibility. The fracture strength of the compacts increased with increasing carbon content of the DRI powder. These observations are discussed with reference to the current understanding of the mechanisms of compaction and fracture of compacted particulate materials.     

Schmelzversuche in eingetieften Rennöfen

Schmelzversuche ohne Gebläse in zwei eingetieften Rennöfen mit 40 cm Durchmesser und 1,20 m Höhe, von denen einer mit einer Hilfsgrube ausgestattet war. Der Ofen ohne Hilfsgrube war nur schwer gängig und hatte eine geringe Windaufnahmefähigkeit. Dagegen konnte durch Auffüllen der Hilfsgrube mit Holzkohle und ihr Zünden das anfängliche Hängen des anderen Ofens beseitigt werden. Es wurden Temperaturen erzielt, bei denen eine Luppenbildung einsetzte. Der hohe Kieselsäure- und niedrige Eisengehalt des benutzten Erzes erwiesen sich als ungünstig zur Bildung flüssiger Schlacken.     

… as QMP offers new high-strength grades

Canadian-based QMP Metal Powders will be promoting a high-strength diffusion-bonded molybdenum steel powder at PM2003 in Valencia later this month. ATOMET DB49 is a newly developed grade that allows the manufacture of PM parts with a tensile strength of more than 850MPa using normal sintering conditions in belt furnaces equipped with a rapid cooling zone. The company will also be exhibiting their own polymeric HGS lubricating system that, they say, “drastically enhances the strength of green parts to the point where they can withstand the stresses applied by cutting tools during machining. QMP will also be showing off a new sponge-type iron powder, ATOMET 24, for high green strength applications that can be used to facilitate the production of more complex parts.This is a short news story only. Visit www.metal-powder.net for the latest powder metallurgy industry news.     

THE EFFECT OF PHOSPHORUS ADDITIONS ON THE TENSILE,FATIGUE, AND IMPACT STRENGTH OF SINTERED STEELS BASED ON SPONGE IRON POWDER AND HIGH-PURITY ATOMIZED IRON POWDER

Abstract

The mechanisms operating during the sintering of iron-phosphorus PM alloys are discussed, as well as the factors contributing to the unique combination of strength, ductility, and toughness that is characteristic of these materials. Alloying methods are reviewed with special reference to powder compressibility, tool wear during compaction, and homogenization during sintering. The preferred production method is to add phosphorus in the form of a fine Fe₃P powder to iron powder. The mechanical properties of a number of sintered steels made with and without Fe₃P additions to sponge iron or to high-purity atomized iron powders are reported. Use of atomized powder makes it possible to reach extremely high density by single pressing and the resulting phosphorus-containing sintered steels have very high ductility and impact strength. The fatigue strength is related linearly to the tensile strength, with a correlation coefficient of 0·91. It is concluded that structural factors other than those that control ductility and toughness are responsible for the fatigue resistance of sintered steels.     

Fe-1.0Cu-2.0Ni-0.55Mo扩散型合金钢粉的研制

本文针对莱粉公司生产的Fe-1.0Cu-2.0Ni-0.55Mo扩散型合金钢粉的生产工艺、粉末性能及其烧结件性能进行了研究。结果表明,采用本工艺生产的扩散型合金钢粉基本保持了基体粉末压缩性高、流动性好的特点,可获得高的压坯密度和烧结体密度;合金粉末损失少且分布均匀,制件尺寸精度高、机械性能稳定;扩散合金化效果好,制件具有较高的硬度和抗拉强度。同时,该生产工艺减少了合金粉末(细粉)的损失和飞扬,生产环境得以很大改善。     

Die Steuerung einer dynamischen Instandhaltungspolitik über Betriebskennzahlen

Entscheidungshilfen bei der Bemessung des Instandhaltungsaufwandes für ein Einzelobjekt. Festlegung von Kenngrößen für Häufigkeit der Instandhaltungsereignisse und Häufigkeit der Minderung der Betriebsmittelnutzungszeit. Ermittlung eines Verrechnungssatzes mit der Zuordnung von Kosten für Instandhaltung zur Zeit der Nutzungsminderung. Instandhaltungsvorgehensweisen und ihre Kombinationen. Graphische Aufbereitung der Kenngrößen in Form von Instandhaltungs-Indikator, Radiuseinheitsvektor und Strategiefeld.