Effects of H2 Atmospheres on Sintering of Low Alloy Steels Containing Oxygen-Sensitive Masteralloys

Processing of novel sintered steels with compositions including oxygen-sensitive elements requires deep understanding of the chemistry of sintering. The use of H₂ atmospheres alleviates the oxygen transference from the base powder to the oxygen-sensitive particles. However, in H₂, methane formation at 700–1200°C causes dramatic homogeneous decarburization of the part that affects both mechanical behavior and dimensional stability. The intensity and the critical temperatures of this effect depend strongly on the alloying elements, being significantly enhanced in presence of Si. When combining the alloying elements as Fe-Mn-Si masteralloys, methane formation is enhanced around 760°C due to the high Mn content (40 wt.%) in the masteralloys. Nevertheless, the benefits of H₂ towards oxide reduction can still be advantageously used if diluting it in the form of N₂-H₂ atmospheres, or if limiting the use of H₂ to temperatures below 500°C. Thus, decarburization due to methane formation can be successfully controlled.