PM 2 Tec 2003: PM industry turning the corner

Abstract

MPIF's 2003 International Conference on Powder Metallurgy and Particulate Materials in Las Vegas attracted 1100 delegates from more than 30 countries. JOSEPH M. CAPUS reviews the event, while JOHN DUNKLEY assesses developments pointing the way to higher density, higher performance PM components.     

Relationship between physical structure and machinability of green compacts

Abstract

The dependence of green machinability on compact density and strength was investigated for room temperature and warm compacted steel powder compacts containing two different types of lubricant. Brazilian disc compression tests were employed to determine green strength, while machinability was assessed in terms of response to drilling.

For the room temperature compacted materials, it was found that high compact densities and strength were not, in most cases, associated with improvements in machinability. Furthermore, it was shown that lubrication (both type and quantity) and compaction pressure plays a critical role in determining the level of breakouts observed. In contrast, the use of warm compaction, in conjunction with specially designed lubricants, has been shown to be a suitable method of producing high density, high strength compacts while retaining good green machining characteristics. Mechanisms responsible for the observed behaviours of both the room temperature and warm compacted specimens have been forwarded in the present paper.     

Wear behaviour of Fe3 Al intermetallic particle reinforced PM based iron metal matrix composites

Abstract

The wear behaviour of unreinforced and reinforced PM based iron metal matrix composite, the latter containing 10 and 20 vol.-% nano sized Fe₃Al intermetallic particles, was studied as a function of sliding distance under two different loads and dry lubricated conditions. The intermetallic Fe₃Al nanoparticles were prepared by mechanical alloying and used as particle reinforcement with 10 and 20 vol.-% in the matrix. The processing of the composites included mixing and cold compaction followed by sintering at 1120°C. The influence of Fe₃Al additions on the dry sliding wear behaviour was studied at loads 20 and 40 N over sliding distances 2160, 3240, 4320 and 6480 m. The study showed that the composite exhibited a lower wear rate than that of the unreinforced matrix and the wear rate was influenced by the volume percentage of Fe₃Al particles. It is understood that iron aluminide reinforcement has a beneficial effect on the wear properties. Delamination and microcutting were the chief mechanisms of wear for the composites.     

Effect of Al2O3 and B4C particle additions on microstructure of PM copper based brake linings

Abstract

This paper highlights the effect of different ceramic particles on the structure of PM copper based brake linings. The copper based brake linings using a range of ceramic additives (1–6 wt-%) were prepared by powder metallurgy (PM). The optimum conditions for the production of brake linings were determined as compaction under 400 MPa and sintering at 805°C for 20 min in an argon atmosphere. The density of copper based brake linings decreased after sintering with the increase in ceramic powder contents for both Al₂O₃ and B₄C ceramic particles. The microstructural characterisation of produced samples showed that the lower boiling point elements in the as supplied powder vaporise during sintering from the structure and this leads to an increase in the porosity amount of the final component.     

Effect of boron on vacuum carburising depth of iron powder metallurgy compacts

Abstract

The work was aimed at determining the effect of boron on vacuum carburising of iron compacts with density over 7·2 g cm^–3. An attempt was made to determine the effectiveness of boron on carbon diffusion rate into the material of compacts with no additional effect of interconnected porosity. Vacuum carburising of compacts made of iron powder with an addition of boron was carried out at 1050°C in a laboratory vacuum furnace.

The effect of boron content within 0·005 to 0·02% on the vacuum carburising depth was analysed. It was found that the boron addition up to 0·01% increased the carburising depth by ～0% in comparison with the compacts of pure iron.     

Influence of sulphur addition by cored wire injection on machinability of grey iron

Abstract

Sulphur powder was added to grey iron melts using cored wire injection technology to improve machinability. The influence of different injection speeds into the ladle on sulphur recovery efficiency was studied, followed by an evaluation of the microstructure, mechanical properties and machinability of the cast iron. The peak sulphur recovery efficiency is 82·5%. Machinability increases with sulphur content.     

Fatigue crack growth in some PM low alloy steels consolidated by rotary forging and sintering

Abstract

Fatigue crack propagation rates under plane strain conditions have been investigated for three PM low alloy steels consolidated to high densities by rotary compaction followed by sintering and heat treatment. It is shown that the densities and properties are intermediate between those of pressed and sintered materials and of powder forged materials. Threshold stress intensities compare satisfactorily with those for wrought counterparts, but resistances to crack growth are inferior to those of wrought steels. Possible reasons for the properties of the rotary compacted materials are considered in the light of their microstructures and the behaviour of other PM materials.     

Characterisation of functionally graded and VC/steel surface alloyed composites produced using powder metallurgy

Abstract

In this study, low carbon steel specimens with surface alloyed composites were produced by means of powder metallurgy. Vanadium carbide, graphite (1·2 wt-%) and Fe were used for the surface alloyed composite, while Fe and graphite (0·2 wt-%) were used for the low carbon steel side. The powder mixtures were compacted together in the same mould. On the surface alloyed side the vanadium carbide content was changed from 5 to 25 wt-%. Microstructural investigations including EDX and X-ray, hardness measurement and abrasive wear tests were performed. The results showed that V₈C₇ formed in the alloyed surface and carbon diffusion from the alloyed surface to the parent metal created a functionally graded material. The hardness values decreased towards the parent metal. Wear resistance increased as the vanadium carbide increased in the surface alloyed composite. Thus, a functionally graded steel having a surface composite that is resistant to abrasive wear can be obtained via the powder metallurgy route.     

Effect of pulsed current on reactively synthesised TiB2 consolidated by plasma pressure compaction

Abstract

The effect of pulsed current on TiB₂ formed by reactive consolidation between titanium and boron is reported in this paper. This consolidation was performed using the plasma pressure compaction (P²C) technique. A comparison between the pulsed and control samples reveals that pulsed current reduces grain growth (pulsed samples had an average grain size of 2·79 μm compared to 5·99 μm) while increasing sintering rates (pulsed samples were on average 15·5% more dense). The reduced grain growth and increased densification is due to the removal of adsorbed oxygen from the surface of the powder.     

Volume changes of binary mixtures during solid state sintering

Abstract

The influence of the mixture concentration on densification of Fe-Cr, Fe-Mo, and Ti-Cu compacts during solid state sintering were investigated. The hypothesis was put forward before that only S and V shaped curves for concentration dependencies of densification exist as a result of solid phase sintering of mixtures. It was shown, in this paper, that the above idea on the existence only two types of the plots was correct. These curve shapes can be explained on the basis of diffusion interaction of metals, applying the multiparticle model of a two component compact.     

Role of reinforcement in sintering of SiC/316L stainless steel composite

Abstract

Austenitic stainless steels with improved corrosion resistance are gaining wide popularity. However, their applications are limited because of their poor tribological properties. The present work was undertaken to improve the overall performance of 316L stainless steel by reinforcing it with SiC. During the processing of the 316L SS composite, the 316L SS matrix was found to interact strongly with the SiC at 1100°C resulting in the formation of low melting Fe–SiC phase. An attempt to process SiC/316L SS composite above this temperature resulted in complete melting of the composite compact.     

碲系易切削钢及其切削性评价

硫系易切削钢利用硫化物的脆断性来提升钢材的切削性能,硫化物的形态、大小、分布是决定易切削钢切削性能优劣的关键因素.上海大学与芜湖新兴铸管有限责任公司合作,通过在1215MS易切削钢基础上添加碲元素,来改善硫化物的形态及分布,提升产品的切削性能.结果表明:硫系易切削钢添加质量分数0.016％ 的碲后,易切削钢中硫化物三维...     

高性能粉末冶金材料与其制造工艺的开发

随着常规粉末冶金产业发展，像锻轧粉末冶金铝合金、超塑性高温合金、机械合金化氧化物弥散强化（ODS）合金之类的先进粉末冶金工艺，引起了人们的注意。受先进粉末冶金工艺启发，开发了适应日本汽车与家电产业的新材料与生产工艺，开发了适合于钢铁结构的粉末冶金Al-Si-X合金。为了改进经济性与近终形（NNS）成形性，开发了无包套粉末挤压工艺与精压式粉末锻造工艺。基于这些工艺，还开发了比单一结构材料具有较多功能的新材料，诸如轻量散热器（heat sink）与高性能发动机气缸内衬。     

Effect of constraint on fracture parameters of piping materials

Fracture behaviour under quasi-static tearing load has been studied through fracture toughness tests on SA333 Grade 6 and 20MnMoNi55 steels using single-edge notched bend (SENB) specimens. To understand the response of variation of constraint, J-R curves were obtained from specimens precracked to a/W ratio in the range of 0.25 to 0.75, in steps of approximately 0.1. Stretch zone widths (SZW) were measured on the fractured surfaces of broken specimens. The stretch zone dimensions that were determined have been used in conjunction with the experimentally derived J-R curve to obtain a value of the ductile fracture toughness parameter J _SZW. The initiation toughness, J _i, obtained at the intersection of the blunting line and the power-law fit to the J-R curve, and the critical toughness, J _c, determined following the procedure of the ASTM standard, were estimated. Comparisons of J _SZW with J _i and J _c have been made for 20MnMoNi55 and SA333 steels as a function of the a/W ratio. The J _i and J _c values are higher at lower a/W, i.e. under low constraint, and fall with increasing a/W. A loss of constraint thus enhances these parameters. It was observed that J _SZW does not effect by a/W, and that its value is lower bound to J _i and J _c values for both the materials investigated.     

Evaluation of temperature effects on selectivity in RPLC separations using polybutadiene-coated zirconia

The effect of temperature on selectivity in RPLC method development has been evaluated on polybutadiene-coated zirconia. We find that the influence of temperature on selectivity depends strongly on solute type. For solutes of similar structure such as polyaromatic hydrocarbons, temperature has almost no effect on selectivity; however, for solutes with very different functional groups such as chlorophenols, temperature changes did significantly affect selectivity. We feel that simple mixtures with one dominant retention mechanism-e.g., solvophobic retention-will not be helped appreciably by adjusting temperature. However, in complex mixtures with polar and ionizable solutes, optimization by varying the temperature may well be fruitful.     

Observations on densification of Al-Al2O3 composite powder compacts by pressure cycling

Abstract

The effectiveness of pressure cycling on the consolidation of powder composites is investigated. Mixed Al and various amounts of Al₂O₃ powders were consolidated under static and cyclic pressure at room temperature in uniaxial consolidation experiments. The results showed that each pressure cycle increases green density and the cyclic effect is stronger when there is a relatively large volume fraction of Al₂O₃ powder. The compacts produced by pressure cycling have much higher strength than those produced with a single pressure excursion and the process ability of compacts should also improve via pressure cycling. Microscopic observations showed that greater uniformity is obtained in compacts by cyclic consolidation. The origin of the beneficial effect of pressure cycling is related to the deviatoric stresses generated by volumetric mismatch due to the different compressibilities of the phases.     

工艺参数对Fe3Al/Al2O3复合材料力学性能的影响研究

以自制的亚微米Fe3Al为增强相、Al2O3为基体相,通过常压烧结制备出Fe3Al/Al2O3复合材料,研究了Fe3Al含量、烧结温度及保温时间对复合材料力学性能的影响.结果表明:增加Fe3Al含量、提高烧结温度及延长保温时间都可以不同程度的提高复合材料力学性能.最佳工艺参数为:Fe3Al含量(质量分数)为15%,成形压力为2488MPa,烧结温度为1380℃.此条件下制备的复合材料的各项力学性能较好:相对密度为93%,维氏硬度为9.3GPa,断裂韧度为7.51MPa·m1/2.烧结温度对提高复合材料力学性能的影响较大.     

Effects of powder processing on densification of titanium diboride based cermets

Abstract

The sinterability of TiB₂-Ni₃(Al,Ti) based cermets has been significantly improved by aggressive milling of the starting TiB₂-Ni-TiAl₃ powder mixtures. This technique improves not only liquid spreading by reducing TiAl₃ particle size but also eliminates alumina agglomerates and the associated porosity found after vacuum sintering. Liquid phase sintering of TiB₂-Ni-TiAl₃ powder mixtures involves the presence of Ni based secondary borides at low temperatures (1200°C), which react afterwards with TiAl₃ particles leading to the formation of the final TiB₂-Ni₃(Al,Ti) eutectic liquid. Apart from improving liquid spreading around TiB₂ grains, aggressive milling is also found to disperse alumina agglomerates, which reduces the porosity associated to these particles. By this refined procedure, the amount of binder phase required for full densification of TiB₂ cermets by sinter hipping has been reduced from a previous limit of 16 vol.-% to 10 vol.-%. The hardness of these TiB₂-10 vol.-%Ni₃(Al,Ti) cermets is in the range of ultrafine WC-Co hardmetals in spite of their much coarser microstructure.     

Effect of inoculating addition on machinability of gray cast iron

Gray cast irons were inoculated with FeSi75+RE and FeSi75+Sr inoculants. The changes of apex angle of the drills before and af-ter being used were used to evaluate machinability of gray cast irons. Effect of FeSi75+RE and FeSi75+Sr inoculants on mechanical proper-ties, machinability and sensibility of gray cast iron used in cylinder block were investigated. Experimental results showed that gray cast iron treated with 60%FeSi75+40% RE inoculants exhibited tensile strength consistently at about 295 MPa along with good hardness and im-proved metallurgical quality. While gray cast iron inoculated with 20%FeSi75+80% Sr inoculants exhibited the best machinability, the low-est cross-section sensibility and the least microhardness difference. The tool flank wear of the drill increased correspondingly with the in-crease of the microhardness difference of the matrix, indicating the great effect of homogeneity of the matrix on the machinability of gray cast iron.     

钻孔密封材料的微观特性及其对密封性能的影响

研究了钻孔密封材料聚氨酯和膨胀水泥冻复合材料(PD复合材料)的微观特性,并考察了其对钻孔密封性能的影响作用.实验模拟了煤矿井下钻孔封孔过程,利用FEIQuanta^TM250环境扫描电子显微镜对聚氨酯、PD复合材料本身,以及两者与煤壁的结合、渗透和发展进行微观对比和分析.PD复合材料的渗透系数约为聚氨酯瓦斯渗透性系数的1/48.聚氨酯为蜂窝网状结构,内部孔隙较大,与孔壁结合处存在空白区域;PD复合材料结构严实,内部孔隙极小,在孔壁处与煤体结合密实.PD复合材料比聚氨酯更容易克服钻孔周围裂隙区内瓦斯压力、水锁效应等各种阻力的作用,在钻孔周围裂隙内逐渐渗透,且其自身可以继续在钻孔周围残余裂隙和孔洞内发展.