THE PREPARATION OF CARBIDE-ENRICHED TOOL STEELS BY POWDER METALLURGY

Abstract

Two PM methods of increasing the carbide content of M2 high-speed steel have been investigated: (1) By the mechanical mixing of tool-steel powder with up to 15 wt.-% of either VC or TiC powders of two different size ranges. (2) By the production of fully prealloyed carbide-enriched powders by gas atomization.

The mixed powders were consolidated by either cold isostatic pressing or explosive compaction, and then vacuum-sintered. Fully dense specimens, however, could be obtained only by subsequent hot working. The pre alloyed powders could not be cold compacted and were densified by hot working the canned loose powders.

With the mixed powders, the carbide dispersion depended closely both on the relative sizes and amounts of the tool-steel and carbide particles and onthe total reduction during hot working. With the fully prealloyed powders a very fine uniform carbide dispersion was obtained in all samples. It was found that with proper composition control the new materials could be heat-treated in a manner similar to that applied to M2 tool steel; significant increases were thus obtained in hardness and wear-resistance. The preferred production methods would be to employ mixed powders for TiC-enriched materials and fully pre alloyed powders for VC-enriched materials.     

The effect of Fe addition on the densification of B4C powder by spark plasma sintering

Boron carbide is a low-density ceramic with high hardness and stiffness values that make it a valuable candidate for light armor applications. Fully dense boron carbide is fabricated by hot pressing of fine (<2 µm) powder at a relatively high temperature (2150–2200°C). Fully dense boron carbide can be processed from an initial mixture of 5.5 vol.% Fe and low-cost B₄C powder by spark plasma sintering (SPS) at 2000°C. At this temperature, Fe-free boron carbide can be consolidated only to 96% of the theoretical density. The effect of the Fe addition on the densities is even more pronounced at lower processing temperatures and is related to the presence of a liquid phase in the Fe-containing material. The resulting microstructure and mechanical properties of the Fe-containing boron carbide are presented and discussed.     

Acceleration of mechanical size reduction of chromium carbide powders and mixtures based on chromium carbide

We have investigated how mechanical activation by rolling on smooth rollers affects the dispersion kinetics of chromium carbide powders and mixtures of chromium carbide powder with nickel in a ball mill. We have shown that preliminary double rolling of chromium carbide powder on a rolling mill accelerates particle size reduction in the ball mill down to a size of 1.4–1.5 μm by a factor of 4.6 compared with unrolled powder. In this case, the size reduction increases from 36 to 91 in relative units. The mean particle diameter for the powders and mixtures decreases exponentially as the grinding time increases from 12 h to 84 h. Translated from Poroshkovaya Metallurgiya, Nos. 1–2(411), pp. 1–8, January–February, 2000.     

Grinding of Fe-B4C powder charge in an inertial cone mill

The use of an inertial cone mill to grind iron and boron carbide powder mixtures is examined. The dependence of the particle-size distribution in the mixture after grinding on the maximum particle size is analyzed. It is established that the content of coarse-grained fractions (larger than 100 µ m) substantially decreases as compared with the initial powder even after three grinding cycles. If the number of grinding cycles is increased to 20, the content of finer fractions (smaller than 63 µ m) is only 6 to 8% higher than in powders subjected to 3–12 grinding cycles in the inertial cone mill. Therefore, more than 3 or 6 cycles to produce Fe-B₄C powder with the optimal content of the ≤100≤63 µ m fraction are unreasonable.     

Al-Fe-Ce alloys based on water-atomized powders for high-temperature applications

The microstructure and mechanical properties of Al-Fe-Ce alloys based on water-atomized powders between 20 and 300 °C are examined in comparison with the properties of similar alloys produced by other rapid crystallization techniques. Changes in atomization parameters vary both the cooling rate (from 10⁴ to 10⁶ K/sec) and powder size distribution (from 5 to 100 µm). The excellent compactability of water-atomized powders facilitates powder consolidation, which is based on hot extrusion and cold pressing of degassed powders. The mechanical properties are examined by tensile tests. The ultimate tensile strength is 500 to 550 MPa at 20 °C and 270 to 300 MPa at 300 °C at adequate plasticity. The properties achieved are comparable with those of similar alloys known from the literature.     

Processing and superplastic properties of fine-grained iron carbide

Fine-grained iron carbide material (80 vol pct iron carbide and 20 vol pct of an iron-base second phase) was prepared using two different powder metallurgy procedures: (1) hot isostatic pressing followed by uniaxial pressing and (2) hot extrusion followed by uniaxial pressing. Both procedures yield materials that are superplastic at elevated temperature with low values of the stress exponent (n = 2 to 1) and tensile elongations as high as 600 pct. The strain rate in then = 2 region is inversely proportional to approximately the cube of the grain size with an activation energy for superplastic flow between 200 and 240 kJ/mol. It is postulated that superplastic flow in the iron carbide material, in then = 2 region, is grain-boundary sliding accommodated by slip controlled by iron diffusion along iron carbide grain boundaries. The flow stress in compression is about 2 times higher than in tension in the region where grain-boundary sliding is the rate-controlling process. It is believed that the difference in flow stress is a result of the greater ease of grain-boundary sliding in tension than in compression. Tensile elongations were observed to increase with a decrease in stress and a decrease in grain size. These effects are quantitatively explained by a fracture mechanics model that has been developed to predict the tensile ductility of superplastic ceramics.     

高密度铁基粉末冶金零部件制造原料的研究

温压粉末原料是采用温压成形技术制造高密度粉末冶金零件的基础和温压工艺的技术核心。高价格的进口温压粉末制约了我国高密度铁基粉末冶金零件的开发与应用,因此,必须开发出符合我国国情的温压粉末原料体系。作者根据我国资源特点,采用鞍钢产水雾化铁粉、水雾化低合金钢粉和攀枝花钢铁公司产转炉烟尘铁粉为原料,进行了制备相应体系的温压粉末原料和温压工艺参数优化的研究。以水雾化铁粉为原料设计制造的Fe-1.5Ni-0.5Mo-0.5Cu-0.6C粉末经637MPa压制,温压密度为7.46g/cm~3;压坯的回弹率为0.03％.在1150℃烧结40 min后,收缩率为0.025％。而以转炉烟尘铁粉设计制造的Fe-1.5Ni-0.5Mo-0.5Cu-0.6C粉末经686 MPa压制,压坯密度达7.35g/cm~3;以Fe-1.5Ni-0.5Mo水雾化合金钢粉为原料制造的Fe-1.5Ni-0.5Mo-1.5Cu-0.8C粉末在686 MPa时压制密度为7.35g/cm~3。这些粉末原料的设计为我国高强度铁基粉末冶金零部件的制造创造了条件。     

Development of Cutting Tool Through Superplastic Boronizing of Duplex Stainless Steel

In this study, a cutting tool is developed from duplex stainless steel (DSS) using the superplastic boronizing technique. The feasibility of the development process is studied, and the cutting performances of the cutting tool are evaluated and compared with commercially available carbide and high-speed steel (HSS) tools. The superplastically boronized (SPB) cutting tool yielded a dense boronized layer of 50.5 µm with a surface hardness of 3956 HV. A coefficient of friction value of 0.62 is obtained, which is lower than 1.02 and 0.8 of the carbide and HSS tools. When tested on an aluminum 6061 surface under dry condition, the SPB cutting tool is also able to produce turning finishing below 0.4 µm, beyond the travel distance of 3000 m, which is comparable to the carbide tool, but produces much better results than HSS tool. Through superplastic boronizing of DSS, it is possible to produce a high-quality metal-based cutting tool that is comparable to the conventional carbide tool.     

Constructional carbide steels: A review of their fabrication,properties, and application

Data on the chemical compositions, structures, properties, and application of industrial carbide Ferro-TiC (United States) and Ferro-Titanit (Germany) steels, which are fabricated by sintering, are presented. The technologies of obtaining such materials based on the processes of sintering under pressure, namely, hot isostatic pressing (HIP), hot extrusion (HE), and hot stamping (HS) are developed. Using the HIP and HE methods, high-speed steel-TiC composites are produced in pilot scales (UkrNIISpetsstal’ and Dneprospetsstal’, Zaporozh’e, Ukraine). In Ukraine and Russia, technologies for obtaining the HS-based carbide steel with the use of TiC and Cr₃C₂ are developed. The prospects for fabrication of new types of composite materials with the use of boron carbide are shown.     

Powder metallurgy T15 tool steel: Part II. Microstructure and properties after heat treatment

The effect of powder particle size and heat treatment on the micro structure and properties of hot isostatically pressed (“hipped”) T15 tool steel has been evaluated. Gas-atomized powder was screened into size fractions covering the range of ≤44 to 1200 /i-m and hipped at 1130 ‡C or 1195 ‡C. The consolidated powders were austenitized at 1175 ‡C or 1225 ‡C and tempered at 538 ‡C, 552 ‡C, or 565 ‡C to control prior austenite grain size, carbide type, carbide volume fraction, and carbide size distribution. Properties measured were bend strength, C-notch impact toughness, and hot hardness. Prior austenite grain size increases with hot isostatic pressing (“hipping”) temperature and austenitizing temperature but is independent of the particle size; similarly, the influence of austenitizing temperature on dissolution of MC and M₆C is independent of the particle size. In each particle size fraction, the volume fraction and size distribution of MC are independent of the tempering temperature. For M₆C, the volume fraction increases and the size distribution is skewed to coarser sizes with increasing tempering temperature. No significant differences in strength and toughness were detected as a function of particle size. Hot hardness is not affected by the particle size. The hot hardness of a powder blend (≤1200 Μm) hipped at 1130 ‡C was superior to that of commercial powder metallurgy (PM) T15 tool steel hipped at 1195 ‡C; this is attributed to a finer carbide size in the noncommercial material. It is established that the subcommercial hipping temperature (1130 ‡C) results in significant microstructural refinement; there is an associated small amount of residual porosity, and this controls the mechanical properties.     

Effect of porosity and grain size on the mechanical properties of hot-pressed boron carbide

Conclusions An investigation was carried out into the effect of porosity in the range 2–46% and grain size in the range (5–140)·10^–6 m on the mechanical properties of boron carbide. It is shown that the level of mechanical properties of boron carbide produced by hot pressing from powders synthesized from the elements is 1.5 times higher than that of boron carbide produced by other methods. Increasing the porosity of boron carbide to 46% decreases its strength by a factor of six or seven. Increasing the grain size to 140·10^–6 m has the same effect. An analysis is made of equations describing the dependence of the mechanical properties of boron carbide on porosity and grain size. The constants of these equations have been determined.Translated from Poroshkovaya Metallurgiya, No. 1(229), pp. 63–67, January, 1982.     

Some features of the milling and pressing of boron carbide

Conclusions A study of the process of comminution of technical boron carbide in a magnetic eddy unit and a planetary activator has demonstrated that experimental plots of the specific surfaces of powders vs milling time are described by Khodakov's equation. The effectiveness of milling of boron carbide is an order higher in a planetary activator than in a magnetic eddy apparatus. However, in a planetary activator the process is accompanied by more intense pickup of iron. The process of densification of boron carbide powders produced by different methods is described by a logarithmic plot of relative volume vs pressing pressure.Translated from Poroshkovaya Metallurgiya, No. 6(270), pp. 29–33, June, 1985.     

NiAl powder alloys: II. Compacting of NiAl powders produced by various methods

The technological properties of granulated NiAl powders produced by gas spraying of melts and NiAl powders produced by calcium hydride reduction (CHR) of mixtures of nickel and aluminum oxides are compared. The possibilities of production of compact workpieces from these powders using hydrostatic pressing, hot pressing, hot isostatic pressing, and hot extrusion are estimated. To improve compressibility, preliminary milling and/or mechanical activation of the powders are proposed. The strength properties of NiAl rods with a diameter of 20 mm extruded from a temperature of 1100°C and made from the granulated powders are slightly higher than those made from the CHR powders. At temperatures higher than 800°C the properties becomes similar. Transition point t _d.b from the ductile to brittle state of samples made from powders sprayed in nitrogen and argon is 100?C150°C higher than those made from the CHR powders. The difference in the mechanical properties is caused by the structural and chemical microheterogeneity of granules (microingots), which is inherited in the rods after hot deformation and annealing at 1200?C1400°C and is (0.67?C0.88)T _m NiAl (T _m is the melting point, K).     

Milling of Carbide-Steel Powder Components and Their Mixtures in an Attrition Mill

Milling of wear-resistant steel and titanium carbide powders is studied with an attrition mill rotation rate of 980 rpm. The physical and technological properties of powders and particle size are determined. Particle shape and the change in material chemical composition during milling are studied. It is established that steel powder cannot be milled to particle sizes less than 3.6 μm whereas a mixture of steel and titanium carbide can be milled to a fine state (0.3 μm). Powders with a size of about 1 μm neither flow nor are formable. Use of benzene as a milling medium makes it possible to prevent steel powder oxidation, but the carbon content in titanium carbide decreases. During milling of the main part of the charge to a fine state rather large steel particles (up to 50 μm) remain.     

Magnetic Properties of Highly Dispersed Ferromagnetics Obtained by the Thermochemical Method

The magnetic properties of highly dispersed powders of iron and iron compositions with silver, platinum, gold, copper, and zinc, obtained by the thermochemical method, are studied. Highly dispersed ferromagnetics are in the class of hard magnetic materials with a particle size of 0.02-0.20 µm. Hence, they fall into the category of single-domain or quasi-single-domain formations. These powders, which have now been produced for the first time, can be used in surgery, endocrinology, oncology, and other fields.     

Structure and properties of tungsten carbide obtained by electric-discharge sintering of a disperse powder

Samples of highly dispersed tungsten carbide powders of various origins were obtained by electrical-discharge sintering. The specimens were 8 mm in diameter, 5 mm in height and had a grain size of 1 µm, density 15.5–15.8 g/cm³, hardness 92–93 HRA, and cracking resistance 6–8 MPa·m^1/2. The structure and phase composition of the sintered samples was not observed to change appreciably from those of the initial powder. The salient features of electrical-discharge sintering of tungsten carbide power are described.     

Friction Stir Processing for Enhancement of Wear Resistance of ZM21 Magnesium Alloy

Present work pertains to surface modification of the magnesium alloy using friction stir processing (FSP). Silicon carbide and boron carbide powders are used in the friction stir processing of the ZM21 Magnesium alloy. Coating was formed by FSP of the alloy by placing the carbide powders into the holes made on the surface. Surface coating was characterized by metallography, hardness and pin-on-disc testing. Friction stir processed coating exhibited excellent wear resistance and is attributed to grain boundary pinning and dispersion hardening caused by carbide particles. Surface composite coating with boron carbide was found to possess better wear resistance than coating made with silicon carbide. This may be attributed to formation of very hard layer coating of boron carbide reinforced composite on the surface of magnesium alloy. In the present work an attempt has also been made to compare the wear behaviour of surface composite layer on ZM21 Mg alloy with that of conventionally used engineering materials such as mild steel and austenitic stainless steel. Wear data clearly shows that wear resistance of friction stir processed composite layer is better than that of mild steel and stainless steel. This work demonstrates that friction stir processing is an effective strategy for enhancement of wear resistance of magnesium alloys.     

Powder metallurgy T15 tool steel: Part I. Characterization of powder and hot isostatically pressed material

The microstructure and constitution of T15 tool steel processed from gas-atomized powder have been characterized. From the atomized powder, four particle size ranges (≤840, 250 to 840, 44 to 100, and ≤44 Μm) were consolidated to full density by hot isostatic pressing (“hipping”) at 1130 ‡C or 1195 ‡C. Both atomized powder and consolidated material were examined by means of optical and electron microscopy, X-ray diffraction, chemical analysis, and micro-hardness. A segregated structure exists in the gas-atomized powder, independent of particle size; MC and M₂C carbides are present, primarily at cell boundaries. The matrix of the powders is a mix of martensite and retained austenite. Weight fraction and overall composition of the carbides are insensitive to particle size, but the proportion of MC carbides increases with decreasing particle size. After consolidation, MC, M₆C, and M₂₃C₆ carbides are present in a ferrite matrix. The carbide size distribution is skewed to larger carbide sizes at the higher consolidation temperature, independent of the prior particle size fraction, but there is no significant change in carbide volume fraction. For a given consolidation temperature, the size distribution of the MC and M₆C carbides is broader for the coarser particle size fractions.     

THE FABRICATION OF HIGH-SPEED TOOL STEEL BY ULTRAFINE POWDER METALLURGY

Abstract

Various powder-metallurgy techniques have been developed during recent years to avoid segregation effects associated with the conventional methods of casting and forming high-speed steels. These techniques have generally involved the consolidation of hot working or hot pressing of 50–500μm prealloyed powders into dense billets or rods.

The work described has demonstrated that much finer, 0·5–5μm, powders of M2 and M50 steels may be cold pressed and sintered to produce bodies with densities of 99% theoretical containing uniformly distributed 1–2μm particles of carbides. It is anticipated that the method will have application for the manufacture of complex-shaped parts with very small material losses and little machining.

An account is given of the preparation of the fine powders by ball-milling and their subsequent compaction, sintering, and microstructure. The control of carbon and oxygen levels by carbon addition to the powders is described.     

The compaction of silicon carbide and compositions based on it: An analysis of domestic and foreign experience

Domestic and foreign experience in compaction of silicon carbide and compositions based on it in order to produce construction and shock resistant materials is generalized. The size, phase, and other characteristics of carbide powders of different producers are compared, and different production variants of compaction (solid-phase sintering, hot isostatic pressing, and sintering in high-pressure chambers), the relation of thermal-force parameters and properties of obtained materials, and the nanolevel of powders and forming structure are considered.