Behaviour of metal powders during cold and warm compaction

Abstract

An instrumented die was used to investigate the behaviour of metal powders during cold (ambienttemperature) and warm (up to 140^°C) compaction. This instrument enables simultaneousmeasurement of density, die wall friction coefficient, the triaxial stresses acting on the powderduring the course of compaction and ejection pressure. Commercial iron, titanium, aluminium,316L stainless steel (SS) and aluminium–silicon powders were employed for investigation. Theresults demonstrated the advantages of powder preheating on the compaction behaviour of metalpowders concerning green density, dimensional changes, frictional behaviour, ejectioncharacteristics and compactibility. However, the outlines also determined that the response ofthe non-ferrous powders to powder preheating is somehow different from those of the ferrouspowders. In this context, the behaviour of prealloy aluminium–silicon powders during compactionwas found of particular interest, as their compactibility is strongly affected by powder preheating,whereas the dimensional changes after ejection decrease considerably. This article presents theeffect of cold and warm compaction on the consolidation and ejection characteristics of ferrousand non-ferrous metal powders. The influence of compaction condition (pressure andtemperature) with considering of the powder characteristics and densification mechanisms areunderlined.     

Investigation of warm compaction and sintering behaviour of aluminium alloys

Abstract

The effects of warm compaction on the green density and sintering behaviour of aluminium alloys were investigated. Particular attention is paid to prealloyed powders, i.e. eutectic and hypereutectic Al-Si alloys, regarding their potential applications in the automotive industry. The effects of chemical composition, alloying method, compacting temperature and the amount of powder lubricant were studied. The compaction behaviour was examined by an instrumented die enabling simultaneous measurement of density, die wall friction coefficient, the triaxial stresses acting on the powder during the course of compaction and ejection pressure. The sintering behaviour was studied via dilatometeric analysis as well as normal batch sintering. The results show that warm compaction could be a promising way to increase the green density of aluminium alloys, especially prealloyed powders, and to decreased imensional instability during sintering. Moreover, it reduces the sliding friction coefficient and the ejection force during the powder shaping process. This paper presents the significant advantages and drawbacks of using the warm compaction process for commercial PM aluminium alloys.     

New method for measuring and characterisation of friction coefficient at wide range of densities in metal powder compaction

Abstract

In order to investigate the friction behaviour of powder during compaction, a new method has been developed. Compaction is a complicated process and direct and continuous measurement of the coefficient of friction is not easy, because the coefficient of friction varies due to changes in such process parameters as pressure distributions, powder surface deformation etc. In this paper, a new device for measuring the coefficient of friction between metal powder particles in contact with the die wall during compaction is presented. Using the conventional methods for direct measurement of the radial pressure during compaction is very difficult. The new device offers the possibility of investigating the normal pressure on the powder particles directly and continuously by keeping the green density constant. The measurements are performed using strain gauges mounted on the upper punch. The upper punch surface in the new device corresponds to the die wall in a conventional press. The sliding velocity, compaction velocity, normal load and temperature can be monitored and controlled. Measurement of the coefficient of friction at low densities is one of the advantages and possible applications of this apparatus. The investigation shows that the powder compaction is controlled by a combination of powder rearrangement and elastic and plastic deformation of particles. At densities below 4g cm^-3 the dominant process is particle rearrangement. No plastic deformation occurs at such low values of density. At densities above 4·5g cm^-3 the plastic deformation of the powder surface in contact with the die wall seems to be completed and the coefficient of friction is more or less constant.     

Effect of compaction process sequence on axial density distribution of green compacts

Abstract

During powder compaction, frictional forces between the compact and the tool elements are developed. This causes pressure gradients in the compact, which produces, at the same time, undesirable density differences. This work presents a study about the effect of the compaction process sequence (CPS) and the ejection process on the axial density distribution during the uniaxial double ended pressing process of a high slenderness bushing. Different pressing processes were selected and carried out with a hydraulic press at laboratory and industrial levels (differences in the extraction method). Compacts were presintered and cut into thin discs in order to measure the local densities along the part, using the Archimedes' method. The obtained results show that the compaction process sequence has an important effect on the axial density distribution in a green compact, mainly in the case of compacts of high slenderness (>5). The ejection causes in the compact a post-compaction modification of the axial density distribution. Therefore, it is necessary to optimise the pressing process to obtain an adequate density distribution for each specific part.     

Effect of Zinc Stearate on Apparent Density,Mixing, and Compaction/Ejection of Iron Powder Compacts

Abstract

The behaviour of zinc stéarate (0–4 wt-%) during mixing with iron powder has been studied by monitoring changes of apparent density and comparison with powder prepared by depositing zinc stéarate from solution onto the iron particles. Apparent density was increased by the development of thin surface films at low lubricant contents but was decreased by the formation of thick layers and free lubricant at high contents. Pressure/density data were obtained from floating-die compaction of cylindrical iron powder compacts containing deposited zinc stéarate with and without die-wall lubrication to determine the relative significance of interparticle friction, particle/die-wall friction, and compaction inhibition. An optimum lubricant addition minimized interparticle friction during compaction. This was greater than the optimum observed for loose packing owing to the more arduous conditions prevalent in compaction. Compaction pressure losses associated with interparticle friction were lower than those caused by die-wall friction. The latter was only minimized by lubricant additions which also caused undesirable compaction inhibition. The forces required to overcome particle/die-wall friction were similar for both compaction and ejection.     

用温压制造高密度材料的关键参数

温压技术是由在加热的阴模中压制预热的粉末组成[1],已知温压有助于零件密实,从而改进烧结件的性能[2,3]。温压需要在适合温压的温度范围内进行。特别是,粉末混合粉应具有好的流动性,同时对阴模模壁有良好润滑性,以减小脱模力。在试验室和工业生产中都研究了用粘结剂处理的和未经粘剂处理的用温压技术制造的材料的性状与性能。为了确定和定量各种关键生产参数,诸如压制压力,粉末温度与阴模温度,生产速率及零件大小对生坯和烧结件特性和零件脱模力的影响,进行了专门的试验研究。依照粉末流动性与松装密度的稳定性,压制压力与温度以及压制零件的重量与密度讨论了温压的工艺性。     

FRICTION COEFFICIENTS BETWEEN IRON POWDER COMPACTS AND DIE WALL DURING EJECTION USING VARIOUS ADMIXED ZINC STEARATE LUBRICANTS

Abstract

Laboratory compaction and ejection studies have been made using a reduced iron powder mixed with a number of zinc stearates having median particle sizes between 4 and 22μm. Comparable experiments were carried out on a fully instrumented production press, which was operated at compacting pressures between 300 and 500 MN/m² to produce compacts with true densities ranging from 5·90 to 6·70 g/cm³. Determination of ejection forces by the two methods enabled calculations of the coefficients of friction between compact and die wall to be made for mixtures containing 0·5–2·0 wt.% zinc stearate. These showed that the behaviour during compaction and ejection was comparable on both laboratory and production scales and gave very similar results. An interpretation of the results is given and values of coefficients of friction are presented which show that these are dependent on the type of zinc stearate used.     

The process of compaction of molybdenum disilicide

Summary A study was made in this investigation of the influence exerted by the time of holding of powder under load, repeated compaction, percentage moisture content, and plasticizer on the compressibility of molybdenum disilicide. In addition, the distribution of forces during compaction and the elastic recovery of compacts were examined.The density of a molybdenum disilicide compact is independent of the time of holding under load, and, consequently the compaction process may be carried out practically instantaneously. It is desirable to employ double or treble compaction with intermediate rubbing through a sieve, the first compaction being performed at a pressure of 35–40 kN/cm² and the second at a pressure of 15–25 kN/cm².It was established that the compaction of molybdenum disilicide is described by semilogarithmic functions of compaction pressure and relative volume. The constants of these equations were determined.The optimum moisture content for the compaction of MoSi₂ powder is 1–3%, and the optimum amount of bentonite addition 3–4%.The use of punch face and die wall lubrication reduces friction between the powder and the die walls, thereby increasing the density of the compact.The minimum elastic recovery (0.4%) is observed at a compaction pressure of 20 kN/cm².The author thanks G. V. Samsonov, Corresponding Member, Acad. Sci. UkrSSR, for his assistance in a number of problems which arose during this investigation and evaluation of the results obtained.     

New technological approach to fabrication of high density PM parts by cold pressing sintering

Abstract

A new technological approach to the fabrication of high density powder metallurgy (PM) parts via single pressing sintering, allowing cold compaction to be performed without admixed lubricants, has been studied. The influence of in pore gas on the compacts' green density and their sintered properties were evaluated. A mathematical expression relating in pore gas pressure in the compacts to the green density was developed. The expression showed that in order to reduce the negative influence of gases trapped in the pores it is necessary to ensure effective air drainage from the compaction zone. In order to ensure sufficient air evacuation during cold compaction, a new design of porous die was developed. The behaviour of powder mixes with different lubricants during cold compaction in porous die was investigated. All the test conditions were evaluated in terms of green and sintered properties, including the ejection force, green and sintered densities, tensile strength and surface hardness. In the context of the experimental work, compaction in porous die promoted the improved combination of green and sintered properties compared with compaction in conventional dies.     

Metal powder compacting dies: optimised design by analytical or numerical methods

Abstract

The initial data needed to design metal powder compaction die are: compact shape and density, powder mix composition, compaction and radial pressure, part number and tool materials. The design targets are: diameters of insert and ring, sometimes number of rings and interference or interferences. The constraints include: no tensile stresses on the insert, no risk of relative motion at part ejection, no unwanted alteration of material microstructures and maximum stresses always below the allowable limits. Usually the design is based on engineering experience, company knowhow, and approximated analytical calculations and cost considerations.

This study is focused on the use of numerical methods to determine the design parameters of dies for powder compaction. Both room temperature and warm compaction have been investigated. Numerical algorithms, implemented into FEM calculation codes, enable one to optimise the common diameter of insert and ring, corresponding to the lowest stresses on both items, or to find the minimum value of the outer diameter. A wide range of compaction pressures, die materials and geometries, interferences and allowable stresses have been explored. To compare the results, based either on analytical or numerical methods, circular dies have been investigated. The differences among the results depend on the consideration of the actual stressed length, or compact height, and total die length. The calculations by analytical methods overestimate the stresses. The paper presents some suitable nomograms for the comparison of results of calculations performed either by Laméformulas or by sophisticated numerical methods.     

AN ASSESSMENT OF GLASS-CERAMIC AS AN INSERT MATERIAL FOR DIE COMPACTION OF METAL POWDERS

Abstract

Glass-ceramic inserts have been made and shrink-fitted into steel bolsters to assess the feasibility of glass-ceramic as a die material for the die-compaction of lubricated and unlubricated iron powder. Measurements of compacting pressures and ejection stresses were lower for the glass-ceramic die compared with those for a standard tool-steel die in lubricated conditions, while in unlubricated conditions ejection stresses were appreciably higher, with scoring and brittle fracture of the insert. The results indicate that possibilities may lie in the further development of ceramics as inexpensive die materials for powder compaction in which die-wall friction could be significantly reduced.     

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.     

Comparison of sintering of titanium and titanium hydride powders

Abstract

The cold compaction and vacuum sintering behaviour of a Ti powder and a Ti hydride powder were compared. Master sintering curve models were developed for both powders. Die ejection force, green strength and green porosity were lower for hydride powder than for Ti powder, all probably resulting from reduced cold welding and friction during compaction. For sintering temperatures above ～1000°C, most of the difference in the sintered density of Ti and hydride is explained by assuming equal densification, while taking into account the lower green porosity of compacts made from hydride powder. However, there is evidence that particle fracture during compaction also contributes to increased sintered density for hydride powder. The Ti powder conformed to a master sintering curve model with apparent activation energy of 160 kJ mol^?. The activation energy for Ti hydride also appeared to be about 160 kJ mol^?, but the model did not fit the experimental data well.     

VARIOUS FACTORS AFFECTING THE WEAR OF STEEL DIES USED FOR THE COMPACTING OF IRON POWDER

Abstract

Small cylindrical iron powder compacts have been produced in series of ～ 75 000 specimens, using an automatic compacting press running at a speed of 33 strokes/min. Die-wear rates were determined, as influenced by powder type, compacting pressure, compact density, type and hardness of die steel, and punch/die clearance. Simultaneously, the ejection forces were continuously recorded.

No substantial difference was found between the die-wear rates of common iron powder grades of an atomized or a sponge type, but an electrolytic grade of especially compact particle structure gave a lower rate. Die wear increases in roughly linear proportion both with the number of compacts and with the compacting pressure.

Steel type and hardness of the die had a pronounced influence upon die-wear behaviour, dies of higher hardness yielding lower wear rates. Unsuitable heat-treatment can cause high wear rates even though it might produce high die hardnesses.

A punch/die clearance of 10 μm resulted in the most favourable die-wear behaviour. At a clearance of only 5 μm the punches became stuck in the die very quickly; at clearances of 25 and 45 μm severe cladding of the die-bore surface with iron from the compacts occurred after 40 000-50 000 strokes.

The following, partly interacting, phenomena were found to be contributory factors in the die-wear mechanism: abrasion, cladding, surface cracking, and chipping. It proved impossible to establish a reliable correlation between ejection forces and die-wear rates.     

Constitutive data and friction measurements of powders using instrumented die

Abstract

An instrumented die has been developed to measure friction and constitutive data on powders during compaction. Such data is useful for quality assurance and as input data for computer models of die compaction. The measurement system consists of a die with radial stress sensors, punch force measurement, and a displacement transducer to measure punch displacement. The outputs of these sensors enable simultaneous measurement of density, die wall friction coefficient, and the triaxial stresses acting on the powder during the course of compaction.

The die system has been tested at three industrial sites on automated and manual presses measuring ferrous, ceramic, and tungsten carbide powders at applied stresses of up to 650 MPa and speeds of up to 26 mm s^-1. Sensor outputs were sufficiently noise free to permit the recording of useful data down to stresses less than 1 MPa. Typically the run to run reproducibility of friction coefficients was better than ± 0·005, depending on the type of powder and the applied stress. Variations in constitutive data were usually better than ± 4%, again depending on material and the stress. Die wall friction coefficients are found generally to decrease with increasing density and stress.

It has been possible to discriminate between different grades and batches of the same material using the frictional and constitutive data. Constitutive data for all types of powder can be accurately represented by an analytical relationship involving four adjustable parameters. This parametric form of data is suitable as input to finite element mathematical models.     

THE EFFECT OF LUBRICATION ON THE PRESSING OF METAL POWDER COMPACTS

Abstract

Admixture of lubricant with metal powder can assist or retard densification according to the applied pressure and the lubricant content. Lubricant exuded on to the die wall under pressure seems to be the main lubricating factor. The change-over or transition pressure from lubrication to inhibition varies in a Gaussian manner with lubricant content. Molecular films of lubricant are sufficient, but for reduction in ejection pressure a minimum content of 0.2% lubricant is necessary. Die-wall lubrication is far more useful and effective than admixed lubricant. Simultaneous die lubrication and admixture is of no value.     

THE COMPACTION OF METAL POWDERS BY ROLLING. II.–AN EXAMINATION OF THE COMPACTION PROCESS

Abstract

The compaction process is examined in detail. It is shown that, where particle deformation is concerned, compaction by rolling is similar to compaction by static pressing, with the addition of elongation of the particles in the rolling direction when the rolling pressure is sufficiently high. A method for determining the average roll pressure is described. A comparison of the rolling of a metal powder with the rolling of a solid bar, and the determination of the effect of particle shape and mean size, indicates that not only roll/powder friction but also the slip between particles plays an important role in the compaction process. This leads to an examination of the flow properties of powders, which are measured in terms of a “powder-viscosity factor” that indicates whether and at what order of rolling speed a powder can be coherently compacted. Finally, a mechanism of compaction is proposed on the basis of the present findings and on the authors’ earlier work.     

Effect of temperature on the behaviour of lubricants during powder compaction

Abstract

The study of the influence of temperature on the performance of admixed lubricants is important since higher densities are desired while keeping the ejection force at a reasonable level. Therefore, three lubricants admixed with iron powder were evaluated during compaction at 25, 65, and 110°C. An instrumented die permitting the measurement of the applied and transmitted pressures through the compact lead to the evaluation of the slide coefficient. This empirical parameter is related to the stress ratio and to the friction coefficient characterising the friction of the compact on the die wall. The evolution of the slide coefficient revealed a different behaviour at the beginning of compaction, where a higher shear resistance is desirable, compared with the end of compaction, which was more influenced by the amount of lubricant at the interface between the compact and the die wall. A too low shear resistance at that stage could however lead to stick–slip phenomenon.     

Effects of powder material and process parameters on the roll compaction,sintering and cold rolling of titanium sponge

ABSTRACT

Roll compaction is a powder metallurgy process that has the potential for cost reduction in the production of titanium parts. In this study, experiments were carried out to investigate the effects of powder type and size on the roll compaction and subsequent sintering and cold rolling behaviour of titanium powder. Powders used ranged in upper sieve sizes from 0.15 to 3?mm. Strip density was found to increase with decreasing powder size while thickness decreased. Following sintering in the range of 800–1200°C, cold rolling was performed with various levels of thickness reduction. Average (across the width) densities of up to 88% were achieved, with higher density regions in the middle of the strips reaching up to 99%. Roll force was measured during cold rolling and found to increase with increasing final (post-cold rolling) density and also with increasing roll gap reduction amounts.