THE CORRELATION BETWEEN RAW MATERIALS,PREPARATION CONDITIONS,AND PROPERTIES OF SINTERED IRON

Abstract

Three plain iron powders of different types (sponge-iron, atomized and electrolytic iron powder) were studied with respect to their sintering behaviour and to the influence of manufacturing parameters—i.e., compacting pressure, sintering temperature, and sintering atmosphere—on the microstructure and the properties of sintered compacts. The changes of length, electric conductivity, and strength during sintering are explained in physical and chemical terms. Technical sintering diagrams are presented. The influence of sintering atmospheres on the mechanical properties of sintered compacts is shown for the three types of powder. The correlation between pore structure and strength is discussed; analytical relationships are developed which are in agreement with the experimental results.     

OBSERVATIONS ON THE SINTERING OF COMPACTSFROM A MIXTURE OF IRON AND COPPER POWDERS

Abstract

Three grades of iron powder-an atomized steel powder, a sponge iron powder reduced from magnetite with carbon, and a powder reduced from mill scale with hydrogen were mixed with 3% of copper powder and pressed into compacts. The diametral dimensional changes of the compacts during sintering below and above the melting point of copper were measured, their microstructures examined, and both related to the characteristics of the powders, particularly their specific surface. During sintering below the melting point of copper, compacts of all three powders shrank. Micrographic examination showed that the copper is transported by solid-state diffusion along the surfacesand grain boundaries of the iron powder particles. During sintering above the melting point of copper, compacts of the atomized and the MH-100 sponge iron powders grew while those of the hydrogen reduced mill-scale powder shrank. This phenomenon is related to the different mode of penetration of liquid copper in the compacts from the three powders, observed in the microstructures of the compacts.     

METHODS OF EXTENDING THE APPLICABILITY OF SINTERED STEELS

Abstract

It is a common opinion among users of structural parts that applications for sintered steels are limited to those where requirements for strength are low to moderate. Furthermore, sintered steels of moderate strength are thought to be very brittle. It is the object of this paper to draw attention to significant improvements which have been achieved in the last few years. These are basically a result of powder developments which are based partly on traditional alloying additions, such as Cu, Ni, Mo, and C, and partly on unique combinations of iron powders and phosphorus or on combinations of iron powders, phosphorus, carbon, and/or copper. Unusually favourable combinations of strength and ductility can be achieved with diffusion-alloys based on iron and phosphorus. Components of high-duty sintered steels capable of replacing components of conventional wrought steels can be produced from partially prealloyed combinations of iron, copper, nickel, molybdenum, and carbon. For many applications these materials can also be an alternative to powder-forged steels. All the above powder combinations show consistent and low dimensional changes during sintering so that close tolerances of intricately shaped components can be maintained. Material and processing costs are such that the improved properties can be achieved economically.     

MECHANICAL PROPERTIES OF SINTER/FORGED LOW-ALLOY STEELS

Abstract

The paper describes preliminary work on sinter/forged low-alloy steels. The mechanical properties and structures of both atomized and blended alloys were investigated. By using a good-quality atomized powder of the SAE 4600 type, tensile and fatigue properties equivalent to those of wrought steels could be obtained. Atomized alloy powders with higher oxygen contents had poor ductility and impact values because of surface oxides on the powder particles.

Blended iron alloys gave tensile strengths up to 72 tonf/in² (1112 MN/m²) with much higher ductility and impact-resistance than would be obtained with conventionally pressed and sintered alloys.     

INFLUENCE OF TIN POWDER CHARACTERISTICS ON THE SINTERING OF IRON-TIN-COPPER POWDER COMPACTS

Abstract

In view of increasing industrial interest in the use of tin additions as an aid to the sintering of iron-based powder compacts, an examination has been made of the influence of the characteristics of the tin powder on sintering performance.

The effect of additions of narrow size-range fractions of atomized tin powder on the dimensional changes and tensile properties obtained on sintering Fe-Sn-Cu compacts made with –100 mesh (–152 μm) or – 300 mesh (– 53 μm) sponge iron and – 300 mesh (– 53 μm) atomized copper powders has been determined. The compacts contained tin and copper in the ratio 2:3. The narrow size fractions were separated from – 300 mesh tin powder by air elutriation. It was found that the use of coarse tin powder reduced the tensile strength of – 300 mesh iron-based Fe–1% Sn–1 ½% Cu compacts, but had no influence when this mixture was based on –100 mesh iron powder, or when the mixture composition was Fe–2% Sn–3% Cu. The effects have been examined in relation to the sintering mechanism by scanning electron microscopy and by X-ray microanalysis.     

THE PRESSING AND SINTERING PROPERTIES OF IRON POWDERS

Abstract

Some twenty different iron powders are available in Europe for the manufacture of sintered bearings and structural parts. These powders can be grouped under four headings: reduced, atomized, comminuted, and electrolytic. Details are given of the experience gained in testing these types of powder by the methods in common use in the metal-powder industry.

The influence of the data thus obtained on the processing, in particular the pressing and sintering conditions, of iron powders is discussed in detail. Consideration is given to the way in which the properties of the powders affect their sinterability, the pressing operation and tool design, and also the physical characteristics of the finished product.     

STUDIES ON THE ACTIVATION-SINTERING OF IRON POWDER

Abstract

A study of the sintering behaviour of iron compacts containing additions of tin up to 1 wt.-% has been made. A tensile strength of 234 MN/m² (34 x 10³ lbf/in²) has been achieved with an optimum tin addition of 0·5 wt.-%, sintering being carried out for 10 min at 1100°C (1373 K) in a reactive halide atmosphere. Combination of the two ‘activating’ techniques (addition of tin and sintering in a reactive atmosphere) permits current properties to be attained at considerably lower sintering temperatures or sintered densities, and is much more effective than when they are applied individually. A tensile strength of 165·3 MN/m² (24 x 10³lbf/in²), achieved by sintering at 1200°C (1473 K) for 10 min with an addition of 0·5 wt.-% tin can be obtained by reactive-sintering the same composition at 900°C (1173 K) for 10 min. Alternatively, the density of the part can be reduced from 6·7 to 6·2 g/cm³ with no loss of strength or elongation. Tin in excess of 0·5 wt.-% causes deterioration in properties under the sintering conditions studied and a reason for this is cited. The improvements in properties are lost also if admixed lubricant is used in the compactionprocess.     

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.     

INFLUENCE OF IRON POWDER TYPE ON THE PROPERTIES OF SINTERED IRON AT VARIOUS DENSITY LEVELS

Abstract

The properties of various commercial and experimental iron powder types and of compacts made from them in the density range 6·8–7·87 kg/dm³ by single-pressing, double-pressing, and hot-forging techniques have been determined. It was shown that the ductility in all cases was more adversely affected than the tensile strength by the presence of porosity. However, it was also shown that at any particular density level or with a given processing schedule the mechanical properties varied widely, depending on the iron powder used. On the basis of the mechanical-property results, the powder types to be preferred at different density levels are indicated.     

EVALUATION OF IRON POWDERS FOR SINTERED STRUCTURAL COMPONENTS

Abstract

A new method for evaluation of iron powders is suggested. Ultimate tensile strength is chosen as a base parameter, and the relations between this property and compacting pressure and raw material cost, respectively, are shown. For this purpose it has been necessary to deduce two supplementary parameters, Relative Pressure Response (P_r) and Relative Raw Material Requirement (M_r), which are functions of compacting pressure and ultimate tensile strength, and of compacting pressure and density, respectively.

It is shown that the importance of compressibility of iron powders is overrated in current opinion and, consequently, that it is misleading to judge the overall merits of an iron powder according to its compressibility.

Raw material costs of sintered steels are lower, if sponge-iron powders are used instead of atomized powders, even if the price of all iron powders were equal. This tendency is more strongly emphasized at low densities, where the sponge-iron powder with the lowest apparent density value is preferable. The differences are beginning to lessen and disappear gradually at densities approaching or exceeding 7·0–7·2 g/cm³ (for single-pressed and single-sintered materials).

Alloy composition has a stronger influence on raw-material costs than the choice of iron-powder grades. Close and reliable control of carbon contents and avoidance of oxidation of manganese is essential for lowering of costs in the PM structural-component manufacturing industry.     

添加高速钢粉对烧结钢组织与性能的影响

研究了添加高速钢粉对烧结钢组织与性能的影响。实验结果表明，含２０％高速钢的烧结钢综合力学性能最好；添加高速钢粉能导致烧结钢密度减小的冲击韧性降低，当高速钢含量增中时，硬度随之增加，烧结钢中残余奥氏体和马氏体的含量与高速钢的含量呈线性关系。烧结钢中的马氏体显微硬度很高，它主要原高速钢粒子和原铁粒子的连接区域形成。     

Transient liquid phase sintering of high density Fe3Al using Fe and Fe2Al5/FeAl2 powders Part 1: Experimentation and results

Abstract

High density Fe₃Al was produced through transient liquid phase sintering, using rapid heating rates of greater than 150 K min^-1 and a mixture of prealloyed and elemental powders. Prealloyed Fe₂Al₅/FeAl₂ (50Fe/50Al, wt-%) powder was added to elemental iron powder in a ratio appropriate for producing an overall Fe₃Al (13·87 wt-%) ratio. The heating rate, sintering time, sintering temperature, green density and powder particle size were controlled during the study. Heating rate, sintering time and powder particle size had the most significant influence upon the sintered density of the compacts. The highest sintered density of 6·12 Mg m^-3 (92% of the theoretical density for Fe3Al) was achieved after 15 minutes of sintering at 1350°C, using a 250 K min^{- 1} heating rate, 1-6 μm Fe powders and 5·66 μm alloy powders.

SEM microscopy suggests that agglomerated Fe₂Al₅/ FeAl₂ particles, which form a liquid during sintering, are responsible for a significant portion of the remaining porosity in high sintered density compacts, creating stable pores, larger than 100 μm diameter, after melting. High density was achieved by minimising the Kirkendall porosity formed during heating by unbalanced diffusion and solubility between the iron and Fe₂Al₅/FeAl₂ components. The lower diffusion rate of aluminium in the prealloyed powder into the iron compared with elemental aluminium in iron, coupled with a fast heating rate, is expected to permit minimal iron-aluminium interdiffusion during heating so that when a liquid forms the aluminium dissolves in the iron to promote solidification at a lower aluminium content. This leads to a further reduction in porosity.     

THE POWDER METALLURGY OF RUTHENIUM

Abstract

An investigation of the powder metallurgy of ruthenium is described, from the reduction of ammonium ruthenium chloride to the working of sintered compacts. The powder properties measured were specific surface area, by a simplified BET method, and tap density. The dependence of these properties on the conditions of reduction has been determined. The surface area of powders varies from 1 to 10 m²/g in the temperature-of-reduction range 700-350°C. The tap density is also variable (1–3 g/c.c.) and is generally related to the surface area. The effects of compacting pressure and temperature on sintering are described, the progress of sintering being observed by measurements of the “open” and “closed” porosity present in samples. Compact densities up to 95% of theoretical can be obtained by sintering at 1500°C. The selection of powder properties and compacting pressures to be used in the production, by vacuum sintering at 1500°C, of high-density compacts for working, is governed by the necessity to maintain open porosity during the heating cycle up to at least 1200°C, as considerable gas evolution occurs at this temperature; at the same time it is essential that good densification shall have occurred even at this stage. These conditions can be met by using powder with a surface area of 2–5 m²/g and compacting pressures in the range 0·5–25 tons/in ².

Observations on the hot working of sintered compacts indicate that ease of working is related to the surface area of the powder.     

FATIGUE BEHAVIOUR OF SINTERED METALS AND ALLOYS

Abstract

Published information on the fatigue behaviour of sintered materials is reviewed.

Porous sintered materials exhibit similar fatigue characteristics to cast and wrought materials, including fatigue limits in ferrous materials. Their endurance ratios are slightly lower than those of similar wrought materials and they may depend on porosity content. In some cases fatigue data for sintered materials show less scatter than those for similar wrought materials. The total porosity content, which is mainly determined by compacting conditions, is the most important factor influencing fatigue behaviour. Endurance limit decreases as the porosity content increases. In the copper- and iron-base materials investigated, fatigue behaviour is influenced only slightly by powder characteristics, sintering temperature, atmosphere, and time, and by post-sintering treatments. Environmental and surface conditions seem to influence the fatigue behaviour in the same manner as pore-free materials. However, notches have a less severe effect than on pore-free materials. Fatigue fracture appears to occur in the same manner as in pore-free materials. Fatigue cracks tend to start at the free surface of the specimen in preference to the internal surfaces of pores, in agreement with theoretical predictions. Sintered low-alloy steels can be heat-treated to give a wide range of fatigue strengths, and they are less notch-sensitive than pore-free steels. The fatigue properties of sintered and pore-free materials are compared and sintered materials are shown to possess fatigue strengths in the same range as cast and wrought materials.     

THE EFFECTS OF IRON-POWDER CONTAMINATION ON THE PROPERTIES OF POWDER-FORGED LOW-ALLOY STEEL

Abstract

Contamination of low-alloy steel powder intended for powder-forging purposes occasionally occurs by virtue of processing through plant normally producing plain iron sintering powders. This paper shows that the effects of moderate amounts of plain iron-powder contamination on the tensile properties of a through-hardened low-alloy steel powder are not significant, provided that the carbon content is maintained at the design level. The results also show that the fatigue endurance limit is lowered although the ratio of fatigue endurance to elastic limit remains constant. In carburizing-grade material, however, there is a significant reduction in the tensile and fatigue strength attainable; and the presence of ‘soft spots’ may have a deleterious effect upon the performance of case-hardened components     

THE ISOSTATIC PRESSING,VACUUM SINTERING,AND SWAGING OF THORIUM POWDER

Abstract

The isostatic pressing of calcium-reduced thorium powder into round bars and tubes, prior to vacuum sintering and swaging, is described. The simple equipment allows powder filling to be carried out in an enclosed system, thus avoiding fire and health hazards at this stage. A number of bars or tubes, of varying length and diameter, can be pressed simultaneously. The technique has certain advantages over conventional die compacting.

The effect of pressure on density and hardness through the bar section before and after sintering at various temperatures has been studied, and the optimum conditions determined for the manufacture of dense bars with high metal efficiencies (98%). Details are given of the microstructure and mechanical properties of thorium bars in the sintered, swaged, and annealed conditions.     

THE EFFECT OF MINOR ADDITIONS OF SULPHUR ON PORE CLOSURE AND CASE-HARDENABILITY OF SINTERED IRON

Abstract

Interconnected porosity in sintered iron structural parts can have a detrimental effect on case-hardening by permitting penetration of the carburizing gases to the interior of the compact. Experiments have shown that small additions of sulphur to the iron powder may provide a means of effecting the desired pore closure, though this method has still to be proved applicable on an industrial scale.     

INFLUENCE OF SINTERING ON FINE POWDER COMPACTS FOR CATALYST APPLICATION

Abstract

The sintering of porous bodies for catalytic purposes requires a compromise between strength and specific surface, since temperature and time have opposing effects on these properties. The present investigation on fine powder compacts of Cr₂O₃ and W was carried out to establish the conditions under which specific surface and strength could be optimized. Hence, sintering temperature and atmosphere were varied. Cylindrical specimens were used to measure specific surface (BET), permeability, and indirect tensile strength. Pore and surface structure were studied by electron-microscopic methods. It has been shown that sintering in nitrogen yields the best results as far as the combination of strength and accessible surface area is concerned. However, if high permeability and high strength are required, hydrogen is the best sintering atmosphere.     

EFFECT OF POROSITY AND PARTICLE SIZE ON THE MECHANICAL STRENGTH OF SINTERED IRON

Abstract

The flexural and tensile strengths and the fatigue limits of sintered iron materials have been measured as a function of porosity and pore size. The resulting experimental values were lower than the theoretical. This discrepancy is attributed to a pore-size effect, analogous to the results of earlier work in which the influence of pore size on elastic modulus was studied (G. Artusio, V. Gallina, G. Mannone, and E. Sgambetterra, Powder Met., 1966, 9, (17), 89).     

烧结高速钢的研究和发展动向

介绍了水雾化－直接烧结粉末高速钢的研究和动向。介绍了提高其烧结性能的方法,包括使用烧结性能的方法,包括使用烧结添加剂、采用氮基烧结气氛、利用计算机预测平衡相图研究新的合金成分等。此外,还介绍了提高材料硬度、强度和断裂韧度的研究以及添加碳化物、氧化物和氮化物对材料性能的影响。