Process
Compaction
Optimizing the production process of NdFeB magnets
(1.10 mb)
Process
Sintering
Advanced Material Options for High Temperature Sintering
i
Materials such as FC-0208 and FN-0205 have been commonly used in the PM industry for many
years. These materials offer a good combination of cost and mechanical properties, but they are
still limited regarding high-end applications. As raw material prices continue to climb and
demand for high strength and ductility parts increases, utilization of next generation materials
coupled with high temperature sintering becomes more attractive. Several material options are
explored and the potential increase in mechanical properties via high temperature sintering is
outlined.
(1.41 mb)
Material Properties
Powder Properties
Microstructure and Mechanical Properties of Dual Phase Steel Produced by Laser Powder Bed Fusion
(1.86 mb)
Process
Powder production
Impact Resistance of a Free Sintering Low Alloy Steel Produced by Powder Bed Fusion Using a Laser Beam
(2.87 mb)
Process
Additive Manufacturing
Impact Resistance of a Free Sintering Low Alloy Steel Produced by Powder Bed Fusion Using a Laser Beam
(2.87 mb)
Material Properties
Mechanical Properties
Impact Resistance of a Free Sintering Low Alloy Steel Produced by Powder Bed Fusion Using a Laser Beam
(2.87 mb)
Process
Sintering
Impact Resistance of a Free Sintering Low Alloy Steel Produced by Powder Bed Fusion Using a Laser Beam
(2.87 mb)
Material Properties
Test Methods
Impact Resistance of a Free Sintering Low Alloy Steel Produced by Powder Bed Fusion Using a Laser Beam
(2.87 mb)
Material Properties
Hardenability
Effect of Chemistry and Processing on Sinter-Hardening Performance of Non- Standardized Alloy Compositions
(728 kb)
Material Properties
Mechanical Properties
Effect of Chemistry and Processing on Sinter-Hardening Performance of Non- Standardized Alloy Compositions
(728 kb)
Process
Sintering
Effect of Chemistry and Processing on Sinter-Hardening Performance of Non- Standardized Alloy Compositions
(728 kb)
Material Properties
Test Methods
Effect of Chemistry and Processing on Sinter-Hardening Performance of Non- Standardized Alloy Compositions
(728 kb)
Process
Additive Manufacturing
Development of an Abrasion Resistant Alloy for the Metal Binder Jet Process
(1.23 mb)
Material Properties
Test Methods
Development of an Abrasion Resistant Alloy for the Metal Binder Jet Process
(1.23 mb)
Material Properties
Powder Properties
Comparison of Soft Magnetic Composites (SMC) and Lamination Assemblies
(695 kb)
Material Properties
Test Methods
Comparison of Soft Magnetic Composites (SMC) and Lamination Assemblies
(695 kb)
Materials
Additives
Production Experience with Advanced Lubricants for Improved Compaction Performance
(1.51 mb)
Process
Compaction
Production Experience with Advanced Lubricants for Improved Compaction Performance
(1.51 mb)
Material Properties
Green Properties
Production Experience with Advanced Lubricants for Improved Compaction Performance
(1.51 mb)
Materials
Alloys
Microstructure and Mechanical Properties of Wear-Resistant Alloys Produced by the Laser Powder Bed Fusion Process
(1.90 mb)
Material Properties
Mechanical Properties
Microstructure and Mechanical Properties of Wear-Resistant Alloys Produced by the Laser Powder Bed Fusion Process
(1.90 mb)
Process
Additive Manufacturing
Microstructure and Mechanical Properties of FSLA Steel Produced by the Binder Jet Process
(806 kb)
Materials
Binder-Treatment & High Density
Microstructure and Mechanical Properties of FSLA Steel Produced by the Binder Jet Process
(806 kb)
Materials
Alloys
Process Experience With High Permeability Soft Magnetic Composites
(426 kb)
Process
Additive Manufacturing
Microstructure and Mechanical Properties of Free-Sintering Low Alloy Steel Produced by Three Additive Manufacturing Methods
(2.91 mb)
Materials
Alloys
Microstructure and Mechanical Properties of Free-Sintering Low Alloy Steel Produced by Three Additive Manufacturing Methods
(2.91 mb)
Material Properties
Hardenability
Microstructure and Mechanical Properties of Free-Sintering Low Alloy Steel Produced by Three Additive Manufacturing Methods
(2.91 mb)
Material Properties
Mechanical Properties
Microstructure and Mechanical Properties of Free-Sintering Low Alloy Steel Produced by Three Additive Manufacturing Methods
(2.91 mb)
Material Properties
Test Methods
Microstructure and Mechanical Properties of Free-Sintering Low Alloy Steel Produced by Three Additive Manufacturing Methods
(2.91 mb)
Process
Additive Manufacturing
Development of a Dual Phase - Low Alloy Steel for Laser Powder Bed Fusion
(2.56 mb)
Materials
Alloys
Development of a Dual Phase - Low Alloy Steel for Laser Powder Bed Fusion
(2.56 mb)
Material Properties
Mechanical Properties
Development of a Dual Phase - Low Alloy Steel for Laser Powder Bed Fusion
(2.56 mb)
Materials
Additives
Advanced Lubricants for Modern PM Applications
(801 kb)
Materials
Binder-Treatment & High Density
Advanced Lubricants for Modern PM Applications
(801 kb)
Process
Compaction
Advanced Lubricants for Modern PM Applications
(801 kb)
Process
Sintering
Advanced Lubricants for Modern PM Applications
(801 kb)
Materials
Alloys
Iron-based powder solutions for soft magnetic composite applications
(461 kb)
Materials
Alloys
Microstructure and Mechanical Properties of Heat Treated FSLA Steel Produced by the Binder Jet Process
(594 kb)
Material Properties
Mechanical Properties
Microstructure and Mechanical Properties of Heat Treated FSLA Steel Produced by the Binder Jet Process
(594 kb)
Materials
Alloys
Development of Wear Resistant Alloys for Use in Laser Powder Bed Fusion
(1.24 mb)
Process
Additive Manufacturing
Development of Dual Phase Steel for LPBF Applications
(1.16 mb)
Materials
Alloys
Development of Dual Phase Steel for LPBF Applications
(1.16 mb)
Materials
Alloys
Application of Sinter-Hardenable Materials for Advanced Automotive Applications such as Gears, Cams, and Sprockets
(42 kb)
Material Properties
Mechanical Properties
Application of Sinter-Hardenable Materials for Advanced Automotive Applications such as Gears, Cams, and Sprockets
(42 kb)
Process
Sintering
Application of Sinter-Hardenable Materials for Advanced Automotive Applications such as Gears, Cams, and Sprockets
(42 kb)
Materials
Alloy Method
New High Performance P/M Alloy Substitutes for Malleable and Ductile Cast Irons
(274 kb)
Materials
Alloys
New High Performance P/M Alloy Substitutes for Malleable and Ductile Cast Irons
(274 kb)
Materials
Binder-Treatment & High Density
New High Performance P/M Alloy Substitutes for Malleable and Ductile Cast Irons
(274 kb)
Process
Sintering
New High Performance P/M Alloy Substitutes for Malleable and Ductile Cast Irons
(274 kb)
Materials
Alloy Method
Binder-treated Analogs of Diffusion Alloyed Compositions Based On Ancorsteel 150 HP
(70 kb)
Materials
Alloys
Binder-treated Analogs of Diffusion Alloyed Compositions Based On Ancorsteel 150 HP
(70 kb)
Materials
Binder-Treatment & High Density
Binder-treated Analogs of Diffusion Alloyed Compositions Based On Ancorsteel 150 HP
(70 kb)
Materials
Alloys
Field Experience on A New Sinter-Hardening Material
(237 kb)
Process
Sintering
Field Experience on A New Sinter-Hardening Material
(237 kb)
Materials
Alloy Method
New High Performance PM Alloys for Replacing Ductile Cast Irons
(174 kb)
Materials
Alloys
New High Performance PM Alloys for Replacing Ductile Cast Irons
(174 kb)
Materials
Binder-Treatment & High Density
New High Performance PM Alloys for Replacing Ductile Cast Irons
(174 kb)
Process
Sintering
New High Performance PM Alloys for Replacing Ductile Cast Irons
(174 kb)
Material Properties
Test Methods
Quantitative Image Analysis Technique for Determining Local Density Variation
(57 kb)
Materials
Alloys
Improved Efficiency by Use of Sinter-Hardened P/M Automotive Components
(404 kb)
Material Properties
Applications
Improved Efficiency by Use of Sinter-Hardened P/M Automotive Components
(404 kb)
Material Properties
Hardenability
Improved Efficiency by Use of Sinter-Hardened P/M Automotive Components
(404 kb)
Material Properties
Mechanical Properties
Improved Efficiency by Use of Sinter-Hardened P/M Automotive Components
(404 kb)
Process
Sintering
Improved Efficiency by Use of Sinter-Hardened P/M Automotive Components
(404 kb)
Materials
Alloys
Hardenability of Sintered Fe-B-C Alloys
(521 kb)
Material Properties
Hardenability
Hardenability of Sintered Fe-B-C Alloys
(521 kb)
Materials
Binder-Treatment & High Density
Advances in Binder-Treatment Technology Statistical Data on Ancorbond Plus
i
Binder treatment technology has been well accepted in the marketplace to provide
reduced segregation and better powder flowability. However, there is a need to increase the green strength of some parts for better handling of intricate shapes and also a need to improve the bonding of nickel and copper. ANCORBOND Plus is an engineered bonding technology that can produce very high green strength and green density based on conventional compaction processing. The system, which uses a zincless lubricant, is based on the optimization of the bonding mechanism and binder chemistry. This paper will present statistical data collected on parts processed in a production press. (2000)
(93 kb)
Material Properties
Dimensional Behavior
Advances in Binder-Treatment Technology Statistical Data on Ancorbond Plus
i
Binder treatment technology has been well accepted in the marketplace to provide
reduced segregation and better powder flowability. However, there is a need to increase the green strength of some parts for better handling of intricate shapes and also a need to improve the bonding of nickel and copper. ANCORBOND Plus is an engineered bonding technology that can produce very high green strength and green density based on conventional compaction processing. The system, which uses a zincless lubricant, is based on the optimization of the bonding mechanism and binder chemistry. This paper will present statistical data collected on parts processed in a production press. (2000)
(93 kb)
Materials
Alloy Method
Ancorloy Premixes - Binder Treated Analogs of the Diffusion Alloyed Steels
i
The properties at two carbon levels of binder treated analogs of the diffusion alloyed steels are presented. These Ancorloy premixes are made according to a proprietary practice that does not include diffusion alloying. It is shown by direct comparison with compositionally similar premixes of the diffusion alloyed steels that the Ancorloys generally exhibit similar powder, green and dimensional change properties and significantly enhanced mechanical properties. Tensile, impact and fatigue property data in the sintered, sintered and tempered and quenched and tempered conditions are presented. (1999)
(163 kb)
Materials
Binder-Treatment & High Density
Ancorloy Premixes - Binder Treated Analogs of the Diffusion Alloyed Steels
i
The properties at two carbon levels of binder treated analogs of the diffusion alloyed steels are presented. These Ancorloy premixes are made according to a proprietary practice that does not include diffusion alloying. It is shown by direct comparison with compositionally similar premixes of the diffusion alloyed steels that the Ancorloys generally exhibit similar powder, green and dimensional change properties and significantly enhanced mechanical properties. Tensile, impact and fatigue property data in the sintered, sintered and tempered and quenched and tempered conditions are presented. (1999)
(163 kb)
Materials
Alloys
High Performance PM Stainless Steels
i
Powder Metallurgy (P/M) automotive exhaust flanges are in volume production for
several US automobile and light truck engines. However competing technologies
continue to improve and may threaten the anticipated increase in applications of P/M
stainless flanges. This paper examines the properties of stainless steel powders,
particularly a stabilised ferritic steel that should improve the processing and
competitiveness of P/M stainless steels in automotive applications. (1999)
(57 kb)
Materials
Binder-Treatment & High Density
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
The objective of this study was to quantify and understand the combined role of microstructure and pore characteristics on the transverse rupture strength (TRS), tensile properties and rotating bend fatigue response of conventional and ANCORDENSE processed FLN2-4405 premixes. To this end, the premixes were made with samples using fine (4μm) and coarse (50μm) nickel powder to promote differences in pore size and diffusion characteristics. Compacts were sintered in synthetic DA (75 v/o H2 / 25 v/o N2) at 2050°F (1120°C) or 2300°F (1260°C) to densities in the range of 6.8 g/cm³ - 7.2 g/cm³. Pore size and spacing, cumulative
pore size and number of pores per unit area were determined by stereological analysis, and the crack path was monitored by means of optical microscopy. The static and dynamic properties of the materials made from the two premixes are interpreted in terms of the attendant microstructures and pore characteristics, as dictated by the premix type, sintering temperature and sintered density. (1999)
(709 kb)
Process
Compaction
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
The objective of this study was to quantify and understand the combined role of microstructure and pore characteristics on the transverse rupture strength (TRS), tensile properties and rotating bend fatigue response of conventional and ANCORDENSE processed FLN2-4405 premixes. To this end, the premixes were made with samples using fine (4μm) and coarse (50μm) nickel powder to promote differences in pore size and diffusion characteristics. Compacts were sintered in synthetic DA (75 v/o H2 / 25 v/o N2) at 2050°F (1120°C) or 2300°F (1260°C) to densities in the range of 6.8 g/cm³ - 7.2 g/cm³. Pore size and spacing, cumulative
pore size and number of pores per unit area were determined by stereological analysis, and the crack path was monitored by means of optical microscopy. The static and dynamic properties of the materials made from the two premixes are interpreted in terms of the attendant microstructures and pore characteristics, as dictated by the premix type, sintering temperature and sintered density. (1999)
(709 kb)
Material Properties
Mechanical Properties
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
The objective of this study was to quantify and understand the combined role of microstructure and pore characteristics on the transverse rupture strength (TRS), tensile properties and rotating bend fatigue response of conventional and ANCORDENSE processed FLN2-4405 premixes. To this end, the premixes were made with samples using fine (4μm) and coarse (50μm) nickel powder to promote differences in pore size and diffusion characteristics. Compacts were sintered in synthetic DA (75 v/o H2 / 25 v/o N2) at 2050°F (1120°C) or 2300°F (1260°C) to densities in the range of 6.8 g/cm³ - 7.2 g/cm³. Pore size and spacing, cumulative
pore size and number of pores per unit area were determined by stereological analysis, and the crack path was monitored by means of optical microscopy. The static and dynamic properties of the materials made from the two premixes are interpreted in terms of the attendant microstructures and pore characteristics, as dictated by the premix type, sintering temperature and sintered density. (1999)
(709 kb)
Material Properties
Test Methods
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
The objective of this study was to quantify and understand the combined role of microstructure and pore characteristics on the transverse rupture strength (TRS), tensile properties and rotating bend fatigue response of conventional and ANCORDENSE processed FLN2-4405 premixes. To this end, the premixes were made with samples using fine (4μm) and coarse (50μm) nickel powder to promote differences in pore size and diffusion characteristics. Compacts were sintered in synthetic DA (75 v/o H2 / 25 v/o N2) at 2050°F (1120°C) or 2300°F (1260°C) to densities in the range of 6.8 g/cm³ - 7.2 g/cm³. Pore size and spacing, cumulative
pore size and number of pores per unit area were determined by stereological analysis, and the crack path was monitored by means of optical microscopy. The static and dynamic properties of the materials made from the two premixes are interpreted in terms of the attendant microstructures and pore characteristics, as dictated by the premix type, sintering temperature and sintered density. (1999)
(709 kb)
Materials
Alloy Method
Performance Characteristics of a New Water-Atomized Prealloyed Powder (0.5 Weight Per Cent Molybdenum)
i
A new prealloy material containing 0.50 w/o Mo was introduced recently. This medium
hardenability material can be admixed with a variety of alloying ingredients to produce superior tensile properties. Results of admixing this prealloyed powder with nickel, copper, manganese, and graphite will be presented. In addition, quench and temper properties will also be discussed. (1999)
(98 kb)
Materials
Alloys
Performance Characteristics of a New Water-Atomized Prealloyed Powder (0.5 Weight Per Cent Molybdenum)
i
A new prealloy material containing 0.50 w/o Mo was introduced recently. This medium
hardenability material can be admixed with a variety of alloying ingredients to produce superior tensile properties. Results of admixing this prealloyed powder with nickel, copper, manganese, and graphite will be presented. In addition, quench and temper properties will also be discussed. (1999)
(98 kb)
Process
Secondary Processing
Performance Characteristics of a New Water-Atomized Prealloyed Powder (0.5 Weight Per Cent Molybdenum)
i
A new prealloy material containing 0.50 w/o Mo was introduced recently. This medium
hardenability material can be admixed with a variety of alloying ingredients to produce superior tensile properties. Results of admixing this prealloyed powder with nickel, copper, manganese, and graphite will be presented. In addition, quench and temper properties will also be discussed. (1999)
(98 kb)
Materials
Binder-Treatment & High Density
A Comparison of Ancordense Processed Materials with Malleable Cast Iron
i
A study was conducted that compared the mechanical properties of a series of
ANCORDENSE prepared materials with malleable cast iron. This paper will present the
mechanical properties (TRS, tensile, impact, and fatigue) of various ANCORDENSE preparedpremixes in the as sintered condition compared with a malleable cast iron. The objective of this investigation was to demonstrate that an engineered P/M material coupled with ANCORDENSE processing can replace a malleable cast iron component giving equivalent mechanical property performance and potentially equivalent gear performance. (1999)
(61 kb)
Process
Compaction
A Comparison of Ancordense Processed Materials with Malleable Cast Iron
i
A study was conducted that compared the mechanical properties of a series of
ANCORDENSE prepared materials with malleable cast iron. This paper will present the
mechanical properties (TRS, tensile, impact, and fatigue) of various ANCORDENSE preparedpremixes in the as sintered condition compared with a malleable cast iron. The objective of this investigation was to demonstrate that an engineered P/M material coupled with ANCORDENSE processing can replace a malleable cast iron component giving equivalent mechanical property performance and potentially equivalent gear performance. (1999)
(61 kb)
Process
Sintering
A Comparison of Ancordense Processed Materials with Malleable Cast Iron
i
A study was conducted that compared the mechanical properties of a series of
ANCORDENSE prepared materials with malleable cast iron. This paper will present the
mechanical properties (TRS, tensile, impact, and fatigue) of various ANCORDENSE preparedpremixes in the as sintered condition compared with a malleable cast iron. The objective of this investigation was to demonstrate that an engineered P/M material coupled with ANCORDENSE processing can replace a malleable cast iron component giving equivalent mechanical property performance and potentially equivalent gear performance. (1999)
(61 kb)
Materials
Alloys
A Superior Sinter-Hardenable Material
i
Sinter-hardening technology has been assisting the P/M parts fabricator by improving
processing efficiencies and reducing costs. Furthermore, the barriers to attaining good sinterhardenability and part performance have been reduced through improvements in materials and equipment developments. Recent material advances have focused on new alloys with increased hardenability and compressibility. A new sinter-hardenable alloy has been introduced which provides improvements in hardenability and compressibility over the well-established FLC-4608 composition. These improvements will allow fabricators to reach higher densities and mechanical performance under typical compaction and sintering conditions. Mechanical performance and material capabilities are investigated as a function of density and admixed composition. Additional processing to achieve higher green densities and mechanical performance will also be reviewed. (1999)
(1.57 mb)
Materials
Binder-Treatment & High Density
A Superior Sinter-Hardenable Material
i
Sinter-hardening technology has been assisting the P/M parts fabricator by improving
processing efficiencies and reducing costs. Furthermore, the barriers to attaining good sinterhardenability and part performance have been reduced through improvements in materials and equipment developments. Recent material advances have focused on new alloys with increased hardenability and compressibility. A new sinter-hardenable alloy has been introduced which provides improvements in hardenability and compressibility over the well-established FLC-4608 composition. These improvements will allow fabricators to reach higher densities and mechanical performance under typical compaction and sintering conditions. Mechanical performance and material capabilities are investigated as a function of density and admixed composition. Additional processing to achieve higher green densities and mechanical performance will also be reviewed. (1999)
(1.57 mb)
Process
Sintering
A Superior Sinter-Hardenable Material
i
Sinter-hardening technology has been assisting the P/M parts fabricator by improving
processing efficiencies and reducing costs. Furthermore, the barriers to attaining good sinterhardenability and part performance have been reduced through improvements in materials and equipment developments. Recent material advances have focused on new alloys with increased hardenability and compressibility. A new sinter-hardenable alloy has been introduced which provides improvements in hardenability and compressibility over the well-established FLC-4608 composition. These improvements will allow fabricators to reach higher densities and mechanical performance under typical compaction and sintering conditions. Mechanical performance and material capabilities are investigated as a function of density and admixed composition. Additional processing to achieve higher green densities and mechanical performance will also be reviewed. (1999)
(1.57 mb)
Materials
Alloys
Application of High Performance Material Processing - Electromagnetic Products
i
The use of powder metallurgy (P/M) parts in AC applications is limited by the inability to reduce the total core loss of the P/M components to levels achieved with conventional laminations. The use of iron powder polymer composites has proven successful in high frequency applications such as ignition coils and high-speed motors. Broader application of P/M in AC applications will require a metedal that will provide superior magnetic performance at low frequencies. This paper will discuss the use of high performance materials for DC applications (in particular, alloys of iron and
silicon) as well as the use of insulated powders for both high and Low frequency applications. (1998)
(679 kb)
Materials
Alloys
What Is Sinter-Hardening?
i
The mechanical properties of ferrous powder metallurgy (P/M) materials are directly
related to their density and microstructure. Many PIM parts are heat treated, in a
secondary operation, to develop a tempered martensitic microstructure either in a
surface layer, or throughout the part. The need for a secondary quenching operation
may be avoided by "sinter-hardening" the parts. Ferrous P/M materials with sufficient hardenability will develop microstructures containing significant percentages of martensite in the as-sintered condition. Accelerated cooling · techniques for sintering furnaces have been developed which permit larger parts to be sinter-hardened, or materials with lower hardenability to be Used to produce sinter-hardened parts with smaller cross-sections. The difference between hardness and hardenability will be explained and a review presented of how the alloying method selected for ferrous P/M materials influences hardenability. Examples of sinter-hardenable materials will be provided and the benefits and disadvantages of the sinter-hardening process will be discussed. (1998)
(976 kb)
Material Properties
Hardenability
What Is Sinter-Hardening?
i
The mechanical properties of ferrous powder metallurgy (P/M) materials are directly
related to their density and microstructure. Many PIM parts are heat treated, in a
secondary operation, to develop a tempered martensitic microstructure either in a
surface layer, or throughout the part. The need for a secondary quenching operation
may be avoided by "sinter-hardening" the parts. Ferrous P/M materials with sufficient hardenability will develop microstructures containing significant percentages of martensite in the as-sintered condition. Accelerated cooling · techniques for sintering furnaces have been developed which permit larger parts to be sinter-hardened, or materials with lower hardenability to be Used to produce sinter-hardened parts with smaller cross-sections. The difference between hardness and hardenability will be explained and a review presented of how the alloying method selected for ferrous P/M materials influences hardenability. Examples of sinter-hardenable materials will be provided and the benefits and disadvantages of the sinter-hardening process will be discussed. (1998)
(976 kb)
Process
Sintering
What Is Sinter-Hardening?
i
The mechanical properties of ferrous powder metallurgy (P/M) materials are directly
related to their density and microstructure. Many PIM parts are heat treated, in a
secondary operation, to develop a tempered martensitic microstructure either in a
surface layer, or throughout the part. The need for a secondary quenching operation
may be avoided by "sinter-hardening" the parts. Ferrous P/M materials with sufficient hardenability will develop microstructures containing significant percentages of martensite in the as-sintered condition. Accelerated cooling · techniques for sintering furnaces have been developed which permit larger parts to be sinter-hardened, or materials with lower hardenability to be Used to produce sinter-hardened parts with smaller cross-sections. The difference between hardness and hardenability will be explained and a review presented of how the alloying method selected for ferrous P/M materials influences hardenability. Examples of sinter-hardenable materials will be provided and the benefits and disadvantages of the sinter-hardening process will be discussed. (1998)
(976 kb)
Materials
Alloys
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
Fatigue testing was performed on FN-0205 premixes in order to evaluate the effect of pore structure and processing method on the fatigue properties. The premixes were made with two nickel sources:
· mean particle size of 4 mm
· mean particle size of 50 mm
Metallographic analysis was performed to quantify the pore structure. The following parameters were examined: pore size, pore shape, mean pore spacing and average pore size. Previous work, which examined a variety of materials, indicated that predicting the fatigue strength of a material is a complex relationship between the type and strength of the microstructural constituents, as well as stereological parameters such as mean pore spacing and pore size. This paper attempts to determine to what extent each of the above parameters influences the fatigue strength of P/M materials. (1998)
(642 kb)
Material Properties
Mechanical Properties
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
Fatigue testing was performed on FN-0205 premixes in order to evaluate the effect of pore structure and processing method on the fatigue properties. The premixes were made with two nickel sources:
· mean particle size of 4 mm
· mean particle size of 50 mm
Metallographic analysis was performed to quantify the pore structure. The following parameters were examined: pore size, pore shape, mean pore spacing and average pore size. Previous work, which examined a variety of materials, indicated that predicting the fatigue strength of a material is a complex relationship between the type and strength of the microstructural constituents, as well as stereological parameters such as mean pore spacing and pore size. This paper attempts to determine to what extent each of the above parameters influences the fatigue strength of P/M materials. (1998)
(642 kb)
Material Properties
Test Methods
The Effect of Microstructure and Pore Morphology on Mechanical and Dynamic Properties of Ferrous PM Materials
i
Fatigue testing was performed on FN-0205 premixes in order to evaluate the effect of pore structure and processing method on the fatigue properties. The premixes were made with two nickel sources:
· mean particle size of 4 mm
· mean particle size of 50 mm
Metallographic analysis was performed to quantify the pore structure. The following parameters were examined: pore size, pore shape, mean pore spacing and average pore size. Previous work, which examined a variety of materials, indicated that predicting the fatigue strength of a material is a complex relationship between the type and strength of the microstructural constituents, as well as stereological parameters such as mean pore spacing and pore size. This paper attempts to determine to what extent each of the above parameters influences the fatigue strength of P/M materials. (1998)
(642 kb)
Materials
Binder-Treatment & High Density
Applications of High Performance Binder Treated Materials
i
Binder treated materials such as ANCORBOND® and ANCORDENSE® increase the performance characteristics of ferrous powder premixes and P/M parts. This paper will discuss the various characteristics of binder treated premixes and their potential applications. A review of the mechanical properties of ANCORDENSE materials will be presented. (1998)
(369 kb)
Process
Compaction
Applications of High Performance Binder Treated Materials
i
Binder treated materials such as ANCORBOND® and ANCORDENSE® increase the performance characteristics of ferrous powder premixes and P/M parts. This paper will discuss the various characteristics of binder treated premixes and their potential applications. A review of the mechanical properties of ANCORDENSE materials will be presented. (1998)
(369 kb)
Materials
Binder-Treatment & High Density
Higher Green Strength and Improved Density by Conventional Compaction
i
A new material system that can produce very high green strength and green density has been developed for conventional compaction processing. The system, which uses a zincless lubricant, is based on the optimization of the bonding mechanism and binder chemistry. This approach permits the bonding of copper particles in a FC-0208 mix. Examples of the binder-treatment of FN-0208, Ancorstee145P, and Ancorstee150
HP are also included. (1998)
(1.55 mb)
Material Properties
Green Properties
Higher Green Strength and Improved Density by Conventional Compaction
i
A new material system that can produce very high green strength and green density has been developed for conventional compaction processing. The system, which uses a zincless lubricant, is based on the optimization of the bonding mechanism and binder chemistry. This approach permits the bonding of copper particles in a FC-0208 mix. Examples of the binder-treatment of FN-0208, Ancorstee145P, and Ancorstee150
HP are also included. (1998)
(1.55 mb)
Materials
Alloys
Application of High Performance Materials and Processes - Alloy Systems
i
Significant advances have been made in the past several years in developing Low alloy materials for highly stressed applications. A review of these material and processing developments will be made. Recent material developments focus on developing high apparent hardness and tensile strength in P/M parts without the need for a secondary quench-hardening operation. The effect of alloy type, alloy
content, and cooling rate on hardness and other properties will be discussed. (1998)
(927 kb)
Material Properties
Hardenability
Application of High Performance Materials and Processes - Alloy Systems
i
Significant advances have been made in the past several years in developing Low alloy materials for highly stressed applications. A review of these material and processing developments will be made. Recent material developments focus on developing high apparent hardness and tensile strength in P/M parts without the need for a secondary quench-hardening operation. The effect of alloy type, alloy
content, and cooling rate on hardness and other properties will be discussed. (1998)
(927 kb)
Process
Sintering
Application of High Performance Materials and Processes - Alloy Systems
i
Significant advances have been made in the past several years in developing Low alloy materials for highly stressed applications. A review of these material and processing developments will be made. Recent material developments focus on developing high apparent hardness and tensile strength in P/M parts without the need for a secondary quench-hardening operation. The effect of alloy type, alloy
content, and cooling rate on hardness and other properties will be discussed. (1998)
(927 kb)
Materials
Alloy Method
The Application of Warm Compaction to High Density Powder Metallurgy Parts
i
The warm compaction process (ANCORDENSE®) has been shown to provide increased density in ferrous powder metallurgy parts. This improvement in density contributes significantly to mechanical properties and thus the overall performance of the part. The combination of increased density with high performance material selections, provides parts that can exceed the performance of forged or cast material counterparts while taking advantage of powder metallurgy's net shape forming capabilities. Turbine hubs for automatic transmission torque converters have
proven to be ideal candidates for the powder metallurgy (P/M) process. The complex shape of turbine hubs is costly to produce via conventional forging and machining operations. However, increases in engine size and torque requirements in several
automotive designs have required that turbine hubs possess higher levels of mechanical properties. High density P/M manufacturing techniques, in combination with high performance ferrous materials produces components capable of replacing a forged and machined turbine hub. This paper will review the conversion of a conventionally forged and machined turbine hub used in a high torque automatic
transmission to a single pressed and single sintered P/M turbine hub. The material used for the P/M hub was an FD-0405. This diffusion alloyed material was evaluated in the laboratory and mechanical properties are reported at several density levels.
Warm compaction processing achieved high overall sintered densities in the highly stressed internal spline region. Extensive mechanical and part specific testing was conducted to verify the suitability of the P/M part. (1997)
(342 kb)
Materials
Binder-Treatment & High Density
The Application of Warm Compaction to High Density Powder Metallurgy Parts
i
The warm compaction process (ANCORDENSE®) has been shown to provide increased density in ferrous powder metallurgy parts. This improvement in density contributes significantly to mechanical properties and thus the overall performance of the part. The combination of increased density with high performance material selections, provides parts that can exceed the performance of forged or cast material counterparts while taking advantage of powder metallurgy's net shape forming capabilities. Turbine hubs for automatic transmission torque converters have
proven to be ideal candidates for the powder metallurgy (P/M) process. The complex shape of turbine hubs is costly to produce via conventional forging and machining operations. However, increases in engine size and torque requirements in several
automotive designs have required that turbine hubs possess higher levels of mechanical properties. High density P/M manufacturing techniques, in combination with high performance ferrous materials produces components capable of replacing a forged and machined turbine hub. This paper will review the conversion of a conventionally forged and machined turbine hub used in a high torque automatic
transmission to a single pressed and single sintered P/M turbine hub. The material used for the P/M hub was an FD-0405. This diffusion alloyed material was evaluated in the laboratory and mechanical properties are reported at several density levels.
Warm compaction processing achieved high overall sintered densities in the highly stressed internal spline region. Extensive mechanical and part specific testing was conducted to verify the suitability of the P/M part. (1997)
(342 kb)
Process
Compaction
The Application of Warm Compaction to High Density Powder Metallurgy Parts
i
The warm compaction process (ANCORDENSE®) has been shown to provide increased density in ferrous powder metallurgy parts. This improvement in density contributes significantly to mechanical properties and thus the overall performance of the part. The combination of increased density with high performance material selections, provides parts that can exceed the performance of forged or cast material counterparts while taking advantage of powder metallurgy's net shape forming capabilities. Turbine hubs for automatic transmission torque converters have
proven to be ideal candidates for the powder metallurgy (P/M) process. The complex shape of turbine hubs is costly to produce via conventional forging and machining operations. However, increases in engine size and torque requirements in several
automotive designs have required that turbine hubs possess higher levels of mechanical properties. High density P/M manufacturing techniques, in combination with high performance ferrous materials produces components capable of replacing a forged and machined turbine hub. This paper will review the conversion of a conventionally forged and machined turbine hub used in a high torque automatic
transmission to a single pressed and single sintered P/M turbine hub. The material used for the P/M hub was an FD-0405. This diffusion alloyed material was evaluated in the laboratory and mechanical properties are reported at several density levels.
Warm compaction processing achieved high overall sintered densities in the highly stressed internal spline region. Extensive mechanical and part specific testing was conducted to verify the suitability of the P/M part. (1997)
(342 kb)
Material Properties
Mechanical Properties
The Application of Warm Compaction to High Density Powder Metallurgy Parts
i
The warm compaction process (ANCORDENSE®) has been shown to provide increased density in ferrous powder metallurgy parts. This improvement in density contributes significantly to mechanical properties and thus the overall performance of the part. The combination of increased density with high performance material selections, provides parts that can exceed the performance of forged or cast material counterparts while taking advantage of powder metallurgy's net shape forming capabilities. Turbine hubs for automatic transmission torque converters have
proven to be ideal candidates for the powder metallurgy (P/M) process. The complex shape of turbine hubs is costly to produce via conventional forging and machining operations. However, increases in engine size and torque requirements in several
automotive designs have required that turbine hubs possess higher levels of mechanical properties. High density P/M manufacturing techniques, in combination with high performance ferrous materials produces components capable of replacing a forged and machined turbine hub. This paper will review the conversion of a conventionally forged and machined turbine hub used in a high torque automatic
transmission to a single pressed and single sintered P/M turbine hub. The material used for the P/M hub was an FD-0405. This diffusion alloyed material was evaluated in the laboratory and mechanical properties are reported at several density levels.
Warm compaction processing achieved high overall sintered densities in the highly stressed internal spline region. Extensive mechanical and part specific testing was conducted to verify the suitability of the P/M part. (1997)
(342 kb)
Materials
Alloys
Sinter-Hardening PM Steels
i
The use of P/M structural parts is growing in part due to the use of the sinter-hardening process which utilizes high performance materials in combination with an accelerated post sintering cooling rate. The sinter-hardening process offers improved
mechanical properties over conventional sintering without a separate heat treatment operation. Thus, where the part design permits, sinter-hardening offers considerable economic benefits to the part producer. Sinter-hardening typically requires that the P/M steel substantially transform to martensite during cooling. A variety of microstructures and properties can be obtained by varying the post sintering cooling rate. By controlling this rate, the microstructure can be manipulated to produce the required amount of martensite to obtain the desired mechanical properties. Alloying elements such as molybdenum, nickel, and copper promote hardenability in P/M parts. By increasing the hardenability of the material, the parts can be cooled at slower rates and still produce large amounts of martensite. The ability to increase the amount of martensite, leading to increased strength and hardness, through the use of proper alloy selection and accelerated cooling rate will be discussed. (1997)
(762 kb)
Material Properties
Mechanical Properties
Sinter-Hardening PM Steels
i
The use of P/M structural parts is growing in part due to the use of the sinter-hardening process which utilizes high performance materials in combination with an accelerated post sintering cooling rate. The sinter-hardening process offers improved
mechanical properties over conventional sintering without a separate heat treatment operation. Thus, where the part design permits, sinter-hardening offers considerable economic benefits to the part producer. Sinter-hardening typically requires that the P/M steel substantially transform to martensite during cooling. A variety of microstructures and properties can be obtained by varying the post sintering cooling rate. By controlling this rate, the microstructure can be manipulated to produce the required amount of martensite to obtain the desired mechanical properties. Alloying elements such as molybdenum, nickel, and copper promote hardenability in P/M parts. By increasing the hardenability of the material, the parts can be cooled at slower rates and still produce large amounts of martensite. The ability to increase the amount of martensite, leading to increased strength and hardness, through the use of proper alloy selection and accelerated cooling rate will be discussed. (1997)
(762 kb)
Process
Sintering
Sinter-Hardening PM Steels
i
The use of P/M structural parts is growing in part due to the use of the sinter-hardening process which utilizes high performance materials in combination with an accelerated post sintering cooling rate. The sinter-hardening process offers improved
mechanical properties over conventional sintering without a separate heat treatment operation. Thus, where the part design permits, sinter-hardening offers considerable economic benefits to the part producer. Sinter-hardening typically requires that the P/M steel substantially transform to martensite during cooling. A variety of microstructures and properties can be obtained by varying the post sintering cooling rate. By controlling this rate, the microstructure can be manipulated to produce the required amount of martensite to obtain the desired mechanical properties. Alloying elements such as molybdenum, nickel, and copper promote hardenability in P/M parts. By increasing the hardenability of the material, the parts can be cooled at slower rates and still produce large amounts of martensite. The ability to increase the amount of martensite, leading to increased strength and hardness, through the use of proper alloy selection and accelerated cooling rate will be discussed. (1997)
(762 kb)
Materials
Alloys
The Effect of Service Temperature on the Properties of Ferritic PM Stainless Steels
i
An area of current development for P/M stainless steel applications is automotive exhaust systems. Recent work in this area has proven the potential application of ferritic stainless steel P/M materials for exhaust flanges to be viable. Lacking in
this work, however, is a sufficient database for P/M stainless steels and, in particular, elevated temperature mechanical properties. A study was undertaken to investigate the effect of service temperature on the mechanical properties of several ferritic P/M
stainless steel grades including 410L, 409Cb, 434L and 434Cb. In particular, tensile properties were generated for these alloys and compared with their wrought equivalents. The effect of process conditions and the subsequent microstructure was also considered. (1997)
(1.15 mb)
Material Properties
Mechanical Properties
The Effect of Service Temperature on the Properties of Ferritic PM Stainless Steels
i
An area of current development for P/M stainless steel applications is automotive exhaust systems. Recent work in this area has proven the potential application of ferritic stainless steel P/M materials for exhaust flanges to be viable. Lacking in
this work, however, is a sufficient database for P/M stainless steels and, in particular, elevated temperature mechanical properties. A study was undertaken to investigate the effect of service temperature on the mechanical properties of several ferritic P/M
stainless steel grades including 410L, 409Cb, 434L and 434Cb. In particular, tensile properties were generated for these alloys and compared with their wrought equivalents. The effect of process conditions and the subsequent microstructure was also considered. (1997)
(1.15 mb)
Process
Sintering
The Effect of Service Temperature on the Properties of Ferritic PM Stainless Steels
i
An area of current development for P/M stainless steel applications is automotive exhaust systems. Recent work in this area has proven the potential application of ferritic stainless steel P/M materials for exhaust flanges to be viable. Lacking in
this work, however, is a sufficient database for P/M stainless steels and, in particular, elevated temperature mechanical properties. A study was undertaken to investigate the effect of service temperature on the mechanical properties of several ferritic P/M
stainless steel grades including 410L, 409Cb, 434L and 434Cb. In particular, tensile properties were generated for these alloys and compared with their wrought equivalents. The effect of process conditions and the subsequent microstructure was also considered. (1997)
(1.15 mb)
Materials
Additives
A Performance Comparison of Current PM Lubricants and Routes to Improvement
i
Greater demands are being placed on lubricant performance because of general industry trends toward more intricate part shapes with related tooling complexity and the incorporation of abrasive additives in mixes. To illustrate the significance of these performance demands, it is necessary to identify the role lubricants play in mixing and the P/M part manufacturing process. This work examines the effects of lubricants on material flow, apparent density, compaction, ejection characteristics and sintered properties. The findings identify key performance elements, which provide a model for developing an improved P/M lubricant. A performance comparison with a commercial lubricant highlights the advantages of a composite lubricant that was evaluated. (1997)
(1.38 mb)
Materials
Alloys
A Performance Comparison of Current PM Lubricants and Routes to Improvement
i
Greater demands are being placed on lubricant performance because of general industry trends toward more intricate part shapes with related tooling complexity and the incorporation of abrasive additives in mixes. To illustrate the significance of these performance demands, it is necessary to identify the role lubricants play in mixing and the P/M part manufacturing process. This work examines the effects of lubricants on material flow, apparent density, compaction, ejection characteristics and sintered properties. The findings identify key performance elements, which provide a model for developing an improved P/M lubricant. A performance comparison with a commercial lubricant highlights the advantages of a composite lubricant that was evaluated. (1997)
(1.38 mb)
Materials
Binder-Treatment & High Density
A Performance Comparison of Current PM Lubricants and Routes to Improvement
i
Greater demands are being placed on lubricant performance because of general industry trends toward more intricate part shapes with related tooling complexity and the incorporation of abrasive additives in mixes. To illustrate the significance of these performance demands, it is necessary to identify the role lubricants play in mixing and the P/M part manufacturing process. This work examines the effects of lubricants on material flow, apparent density, compaction, ejection characteristics and sintered properties. The findings identify key performance elements, which provide a model for developing an improved P/M lubricant. A performance comparison with a commercial lubricant highlights the advantages of a composite lubricant that was evaluated. (1997)
(1.38 mb)
Material Properties
Green Properties
A Performance Comparison of Current PM Lubricants and Routes to Improvement
i
Greater demands are being placed on lubricant performance because of general industry trends toward more intricate part shapes with related tooling complexity and the incorporation of abrasive additives in mixes. To illustrate the significance of these performance demands, it is necessary to identify the role lubricants play in mixing and the P/M part manufacturing process. This work examines the effects of lubricants on material flow, apparent density, compaction, ejection characteristics and sintered properties. The findings identify key performance elements, which provide a model for developing an improved P/M lubricant. A performance comparison with a commercial lubricant highlights the advantages of a composite lubricant that was evaluated. (1997)
(1.38 mb)
Materials
Alloy Method
The Effect of Nickel Content, Sintering Temperature and Density on the Properties of a Warm Compacted 0.85 w,o Molybdenum Prealloy
i
The combination of molybdenum prealloyed steel powders and admixed nickel provides sintered steels that are used in structural parts requiring strength, wear resistance, and impact toughness. The properties of these materials, like all P/M steels, are dependent on density, microstructure and composition. This work discusses the effect of admixed nickel content, sintering temperature, and density on
the properties of a 0.85 w/o molybdenum prealloy. Samples were prepared with 0, 2, 4 and 6 w/o nickel additions. The materials were warm compacted at 30, 40, 45, and 50 tsi (415, 550, 620 and 690 MPa) and sintered at 1900°F, 2100°F and 2300°F (1040°C, 1150°C, and 1260°C). Mechanical properties were determined and related to the density, microstructure, and composition. (1997)
(1.11 mb)
Materials
Alloys
The Effect of Nickel Content, Sintering Temperature and Density on the Properties of a Warm Compacted 0.85 w,o Molybdenum Prealloy
i
The combination of molybdenum prealloyed steel powders and admixed nickel provides sintered steels that are used in structural parts requiring strength, wear resistance, and impact toughness. The properties of these materials, like all P/M steels, are dependent on density, microstructure and composition. This work discusses the effect of admixed nickel content, sintering temperature, and density on
the properties of a 0.85 w/o molybdenum prealloy. Samples were prepared with 0, 2, 4 and 6 w/o nickel additions. The materials were warm compacted at 30, 40, 45, and 50 tsi (415, 550, 620 and 690 MPa) and sintered at 1900°F, 2100°F and 2300°F (1040°C, 1150°C, and 1260°C). Mechanical properties were determined and related to the density, microstructure, and composition. (1997)
(1.11 mb)
Materials
Binder-Treatment & High Density
The Effect of Nickel Content, Sintering Temperature and Density on the Properties of a Warm Compacted 0.85 w,o Molybdenum Prealloy
i
The combination of molybdenum prealloyed steel powders and admixed nickel provides sintered steels that are used in structural parts requiring strength, wear resistance, and impact toughness. The properties of these materials, like all P/M steels, are dependent on density, microstructure and composition. This work discusses the effect of admixed nickel content, sintering temperature, and density on
the properties of a 0.85 w/o molybdenum prealloy. Samples were prepared with 0, 2, 4 and 6 w/o nickel additions. The materials were warm compacted at 30, 40, 45, and 50 tsi (415, 550, 620 and 690 MPa) and sintered at 1900°F, 2100°F and 2300°F (1040°C, 1150°C, and 1260°C). Mechanical properties were determined and related to the density, microstructure, and composition. (1997)
(1.11 mb)
Process
Compaction
The Effect of Nickel Content, Sintering Temperature and Density on the Properties of a Warm Compacted 0.85 w,o Molybdenum Prealloy
i
The combination of molybdenum prealloyed steel powders and admixed nickel provides sintered steels that are used in structural parts requiring strength, wear resistance, and impact toughness. The properties of these materials, like all P/M steels, are dependent on density, microstructure and composition. This work discusses the effect of admixed nickel content, sintering temperature, and density on
the properties of a 0.85 w/o molybdenum prealloy. Samples were prepared with 0, 2, 4 and 6 w/o nickel additions. The materials were warm compacted at 30, 40, 45, and 50 tsi (415, 550, 620 and 690 MPa) and sintered at 1900°F, 2100°F and 2300°F (1040°C, 1150°C, and 1260°C). Mechanical properties were determined and related to the density, microstructure, and composition. (1997)
(1.11 mb)
Material Properties
Mechanical Properties
The Effect of Nickel Content, Sintering Temperature and Density on the Properties of a Warm Compacted 0.85 w,o Molybdenum Prealloy
i
The combination of molybdenum prealloyed steel powders and admixed nickel provides sintered steels that are used in structural parts requiring strength, wear resistance, and impact toughness. The properties of these materials, like all P/M steels, are dependent on density, microstructure and composition. This work discusses the effect of admixed nickel content, sintering temperature, and density on
the properties of a 0.85 w/o molybdenum prealloy. Samples were prepared with 0, 2, 4 and 6 w/o nickel additions. The materials were warm compacted at 30, 40, 45, and 50 tsi (415, 550, 620 and 690 MPa) and sintered at 1900°F, 2100°F and 2300°F (1040°C, 1150°C, and 1260°C). Mechanical properties were determined and related to the density, microstructure, and composition. (1997)
(1.11 mb)
Process
Sintering
The Effect of Nickel Content, Sintering Temperature and Density on the Properties of a Warm Compacted 0.85 w,o Molybdenum Prealloy
i
The combination of molybdenum prealloyed steel powders and admixed nickel provides sintered steels that are used in structural parts requiring strength, wear resistance, and impact toughness. The properties of these materials, like all P/M steels, are dependent on density, microstructure and composition. This work discusses the effect of admixed nickel content, sintering temperature, and density on
the properties of a 0.85 w/o molybdenum prealloy. Samples were prepared with 0, 2, 4 and 6 w/o nickel additions. The materials were warm compacted at 30, 40, 45, and 50 tsi (415, 550, 620 and 690 MPa) and sintered at 1900°F, 2100°F and 2300°F (1040°C, 1150°C, and 1260°C). Mechanical properties were determined and related to the density, microstructure, and composition. (1997)
(1.11 mb)
Materials
Additives
Processing Experience of Green Strength Enhanced Material Systems
i
Green strength enhanced material systems have been developed for iron and Low alloy as well as stainless powder metallurgy applications. Relative to normal processing, the increase in green strength is 50-100%. The nature of green
strength with respect to both materials and processing conditions is reviewed. The processing variations designed to meet target properties such as apparent density, flow and compressibility are compared with conventional material systems. Manufacturing experience with a mechanical press is presented. (1997)
(1.55 mb)
Materials
Alloys
Processing Experience of Green Strength Enhanced Material Systems
i
Green strength enhanced material systems have been developed for iron and Low alloy as well as stainless powder metallurgy applications. Relative to normal processing, the increase in green strength is 50-100%. The nature of green
strength with respect to both materials and processing conditions is reviewed. The processing variations designed to meet target properties such as apparent density, flow and compressibility are compared with conventional material systems. Manufacturing experience with a mechanical press is presented. (1997)
(1.55 mb)
Process
Compaction
Processing Experience of Green Strength Enhanced Material Systems
i
Green strength enhanced material systems have been developed for iron and Low alloy as well as stainless powder metallurgy applications. Relative to normal processing, the increase in green strength is 50-100%. The nature of green
strength with respect to both materials and processing conditions is reviewed. The processing variations designed to meet target properties such as apparent density, flow and compressibility are compared with conventional material systems. Manufacturing experience with a mechanical press is presented. (1997)
(1.55 mb)
Material Properties
Green Properties
Processing Experience of Green Strength Enhanced Material Systems
i
Green strength enhanced material systems have been developed for iron and Low alloy as well as stainless powder metallurgy applications. Relative to normal processing, the increase in green strength is 50-100%. The nature of green
strength with respect to both materials and processing conditions is reviewed. The processing variations designed to meet target properties such as apparent density, flow and compressibility are compared with conventional material systems. Manufacturing experience with a mechanical press is presented. (1997)
(1.55 mb)
Materials
Alloys
The Effect of Microstructure on Fatigue Properties of Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) was performed on several materials in order to evaluate the effect of several microstructural elements. Metallographic analysis was performed to characterize the microstructures of the materials and attempt to identify failure mechanisms. Previous work indicated that predicting the fatigue strength of P/M materials is a complex relationship between the grain size of the
material, the type and strength of the microstructural constituents present and, primarily, the mean pore spacing. [1,2] This study examines these relationships in more depth. (1997)
(967 kb)
Material Properties
Mechanical Properties
The Effect of Microstructure on Fatigue Properties of Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) was performed on several materials in order to evaluate the effect of several microstructural elements. Metallographic analysis was performed to characterize the microstructures of the materials and attempt to identify failure mechanisms. Previous work indicated that predicting the fatigue strength of P/M materials is a complex relationship between the grain size of the
material, the type and strength of the microstructural constituents present and, primarily, the mean pore spacing. [1,2] This study examines these relationships in more depth. (1997)
(967 kb)
Material Properties
Test Methods
The Effect of Microstructure on Fatigue Properties of Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) was performed on several materials in order to evaluate the effect of several microstructural elements. Metallographic analysis was performed to characterize the microstructures of the materials and attempt to identify failure mechanisms. Previous work indicated that predicting the fatigue strength of P/M materials is a complex relationship between the grain size of the
material, the type and strength of the microstructural constituents present and, primarily, the mean pore spacing. [1,2] This study examines these relationships in more depth. (1997)
(967 kb)
Materials
Alloys
The Manufacture of Electromagnetic Components by the Powder Metallurgy Process
i
The powder metallurgy process provides the ability to manufacture net shape parts from a variety of materials in a cost effective manner. A market segment that has exhibited the ability to take advantage of powder metallurgy's flexibility has been in
electromagnetic applications. This area has shown significant growth in the past decade that should continue for the foreseeable future. This paper will discuss materials and processes that have proven successful in several electromagnetic applications. Both sintered materials for DC type applications and insulated materials for AC applications will be reviewed along with appropriate processing techniques for each. Specific applications for both materials will be presented. (1997)
(375 kb)
Materials
Binder-Treatment & High Density
The Manufacture of Electromagnetic Components by the Powder Metallurgy Process
i
The powder metallurgy process provides the ability to manufacture net shape parts from a variety of materials in a cost effective manner. A market segment that has exhibited the ability to take advantage of powder metallurgy's flexibility has been in
electromagnetic applications. This area has shown significant growth in the past decade that should continue for the foreseeable future. This paper will discuss materials and processes that have proven successful in several electromagnetic applications. Both sintered materials for DC type applications and insulated materials for AC applications will be reviewed along with appropriate processing techniques for each. Specific applications for both materials will be presented. (1997)
(375 kb)
Process
Compaction
The Manufacture of Electromagnetic Components by the Powder Metallurgy Process
i
The powder metallurgy process provides the ability to manufacture net shape parts from a variety of materials in a cost effective manner. A market segment that has exhibited the ability to take advantage of powder metallurgy's flexibility has been in
electromagnetic applications. This area has shown significant growth in the past decade that should continue for the foreseeable future. This paper will discuss materials and processes that have proven successful in several electromagnetic applications. Both sintered materials for DC type applications and insulated materials for AC applications will be reviewed along with appropriate processing techniques for each. Specific applications for both materials will be presented. (1997)
(375 kb)
Materials
Binder-Treatment & High Density
Recent Applications of Binder Treatment Technology
i
The development of a practical binder treatment process in the late 1980's has since led to the commercialization of several new premix technologies that have had a major impact on P/M competitiveness. To date, a great deal has been written about
these technologies. However, until now, there has been little to suggest that they are inherently interrelated by a common approach, or that this approach has untapped potential for still newer and better technologies. In addition, it also happens that in spite of all that has been written on the existing technologies, there is nothing that serves as a comprehensive single source of information on all of them. Consequently, the purpose of the present paper is to document the indicated approach as well as to present a summary description of each of the technologies complete with one or more production case histories of recent origin. The aim of the latter is to present discriminating up-to-date examples of general interest as well as
to highlight one or more of the various advantages of the associated technology. (1997)
(542 kb)
Process
Compaction
Recent Applications of Binder Treatment Technology
i
The development of a practical binder treatment process in the late 1980's has since led to the commercialization of several new premix technologies that have had a major impact on P/M competitiveness. To date, a great deal has been written about
these technologies. However, until now, there has been little to suggest that they are inherently interrelated by a common approach, or that this approach has untapped potential for still newer and better technologies. In addition, it also happens that in spite of all that has been written on the existing technologies, there is nothing that serves as a comprehensive single source of information on all of them. Consequently, the purpose of the present paper is to document the indicated approach as well as to present a summary description of each of the technologies complete with one or more production case histories of recent origin. The aim of the latter is to present discriminating up-to-date examples of general interest as well as
to highlight one or more of the various advantages of the associated technology. (1997)
(542 kb)
Material Properties
Green Properties
Recent Applications of Binder Treatment Technology
i
The development of a practical binder treatment process in the late 1980's has since led to the commercialization of several new premix technologies that have had a major impact on P/M competitiveness. To date, a great deal has been written about
these technologies. However, until now, there has been little to suggest that they are inherently interrelated by a common approach, or that this approach has untapped potential for still newer and better technologies. In addition, it also happens that in spite of all that has been written on the existing technologies, there is nothing that serves as a comprehensive single source of information on all of them. Consequently, the purpose of the present paper is to document the indicated approach as well as to present a summary description of each of the technologies complete with one or more production case histories of recent origin. The aim of the latter is to present discriminating up-to-date examples of general interest as well as
to highlight one or more of the various advantages of the associated technology. (1997)
(542 kb)
Material Properties
Powder Properties
Recent Applications of Binder Treatment Technology
i
The development of a practical binder treatment process in the late 1980's has since led to the commercialization of several new premix technologies that have had a major impact on P/M competitiveness. To date, a great deal has been written about
these technologies. However, until now, there has been little to suggest that they are inherently interrelated by a common approach, or that this approach has untapped potential for still newer and better technologies. In addition, it also happens that in spite of all that has been written on the existing technologies, there is nothing that serves as a comprehensive single source of information on all of them. Consequently, the purpose of the present paper is to document the indicated approach as well as to present a summary description of each of the technologies complete with one or more production case histories of recent origin. The aim of the latter is to present discriminating up-to-date examples of general interest as well as
to highlight one or more of the various advantages of the associated technology. (1997)
(542 kb)
Materials
Alloys
Powder Metallurgy Materials for AC Magnetic Applications
i
Ancorsteel Insulated Powders provide the ability to utilize ferrous powder metallurgy materials in alternating magnetic field applications. These materials, unlike sintered components, offer the ability to control eddy current generation at high frequencies. The development process involved in the evolution of these materials is reviewed along with magnetic and physical properties. Potential part applications are presented with special emphasis placed on utilizing powder metallurgy's unique shape making capabilities. (1996)
(91 kb)
Materials
Binder-Treatment & High Density
The Effect of Microstructure on Fatigue Properties of High Density Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) has been performed on several high
performance ferrous P/M material systems. Detailed metallographic analysis was
performed to determine differences in the failure mechanisms for various material and
process combinations. A variety of material compositions were single compacted to
high density via the ANCORDENSE compaction system. This was followed by
conventional and high temperature sintering and testing in the as-sintered and heat
treated conditions. The analysis provides information as to the relationships between
density, structure and composition with fatigue life. (1996)
(945 kb)
Material Properties
Mechanical Properties
The Effect of Microstructure on Fatigue Properties of High Density Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) has been performed on several high
performance ferrous P/M material systems. Detailed metallographic analysis was
performed to determine differences in the failure mechanisms for various material and
process combinations. A variety of material compositions were single compacted to
high density via the ANCORDENSE compaction system. This was followed by
conventional and high temperature sintering and testing in the as-sintered and heat
treated conditions. The analysis provides information as to the relationships between
density, structure and composition with fatigue life. (1996)
(945 kb)
Process
Sintering
The Effect of Microstructure on Fatigue Properties of High Density Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) has been performed on several high
performance ferrous P/M material systems. Detailed metallographic analysis was
performed to determine differences in the failure mechanisms for various material and
process combinations. A variety of material compositions were single compacted to
high density via the ANCORDENSE compaction system. This was followed by
conventional and high temperature sintering and testing in the as-sintered and heat
treated conditions. The analysis provides information as to the relationships between
density, structure and composition with fatigue life. (1996)
(945 kb)
Material Properties
Test Methods
The Effect of Microstructure on Fatigue Properties of High Density Ferrous PM Materials
i
Fatigue testing (rotating bending fatigue) has been performed on several high
performance ferrous P/M material systems. Detailed metallographic analysis was
performed to determine differences in the failure mechanisms for various material and
process combinations. A variety of material compositions were single compacted to
high density via the ANCORDENSE compaction system. This was followed by
conventional and high temperature sintering and testing in the as-sintered and heat
treated conditions. The analysis provides information as to the relationships between
density, structure and composition with fatigue life. (1996)
(945 kb)
Materials
Alloy Method
The Development of High Performance PM Steels
i
Ferrous powder metallurgy has continued to displace competing cast or wrought technologies in automotive applications. This required the development of materials systems with higher, more consistent performance than those available previously. However, competing technologies are not static. The paper examines the materials
development and microstructural control required to meet the challenges and opportunities offered by the development of new P/M parts. (1996)
(1.45 mb)
Materials
Binder-Treatment & High Density
The Development of High Performance PM Steels
i
Ferrous powder metallurgy has continued to displace competing cast or wrought technologies in automotive applications. This required the development of materials systems with higher, more consistent performance than those available previously. However, competing technologies are not static. The paper examines the materials
development and microstructural control required to meet the challenges and opportunities offered by the development of new P/M parts. (1996)
(1.45 mb)
Process
Compaction
The Development of High Performance PM Steels
i
Ferrous powder metallurgy has continued to displace competing cast or wrought technologies in automotive applications. This required the development of materials systems with higher, more consistent performance than those available previously. However, competing technologies are not static. The paper examines the materials
development and microstructural control required to meet the challenges and opportunities offered by the development of new P/M parts. (1996)
(1.45 mb)
Material Properties
Mechanical Properties
The Development of High Performance PM Steels
i
Ferrous powder metallurgy has continued to displace competing cast or wrought technologies in automotive applications. This required the development of materials systems with higher, more consistent performance than those available previously. However, competing technologies are not static. The paper examines the materials
development and microstructural control required to meet the challenges and opportunities offered by the development of new P/M parts. (1996)
(1.45 mb)
Process
Secondary Processing
The Development of High Performance PM Steels
i
Ferrous powder metallurgy has continued to displace competing cast or wrought technologies in automotive applications. This required the development of materials systems with higher, more consistent performance than those available previously. However, competing technologies are not static. The paper examines the materials
development and microstructural control required to meet the challenges and opportunities offered by the development of new P/M parts. (1996)
(1.45 mb)
Process
Sintering
The Development of High Performance PM Steels
i
Ferrous powder metallurgy has continued to displace competing cast or wrought technologies in automotive applications. This required the development of materials systems with higher, more consistent performance than those available previously. However, competing technologies are not static. The paper examines the materials
development and microstructural control required to meet the challenges and opportunities offered by the development of new P/M parts. (1996)
(1.45 mb)
Materials
Alloys
Single Compaction to Achieve High Density in Ferrous PM Materials in Automotive Applications
i
The continued growth of ferrous powder metallurgy in automotive applications is
dependent on the development of higher density and improved dynamic properties.
New powder metallurgy applications also must be cost effective through the continued use of the process's, net shape forming capabilities and a reduced number of manufacturing steps. The processes utilized to manufacture some of these new parts also must provide the ability to produce thin walled parts with complex geometries. The use of the warm compaction process (ANCORDENSE™) will be shown to develop high density levels with a single compaction process. The process also provides increased green strength and reduced ejection forces. The dependence of mechanical properties on density will be demonstrated. An example of a potential application of the warm compaction technology is an output shaft. The capability of manufacturing this part with the warm compaction process is outlined and compared with the same part made by the double press/double sinter (DPDS) process. Part density and performance from both processes are compared. (1996)
(319 kb)
Materials
Binder-Treatment & High Density
Single Compaction to Achieve High Density in Ferrous PM Materials in Automotive Applications
i
The continued growth of ferrous powder metallurgy in automotive applications is
dependent on the development of higher density and improved dynamic properties.
New powder metallurgy applications also must be cost effective through the continued use of the process's, net shape forming capabilities and a reduced number of manufacturing steps. The processes utilized to manufacture some of these new parts also must provide the ability to produce thin walled parts with complex geometries. The use of the warm compaction process (ANCORDENSE™) will be shown to develop high density levels with a single compaction process. The process also provides increased green strength and reduced ejection forces. The dependence of mechanical properties on density will be demonstrated. An example of a potential application of the warm compaction technology is an output shaft. The capability of manufacturing this part with the warm compaction process is outlined and compared with the same part made by the double press/double sinter (DPDS) process. Part density and performance from both processes are compared. (1996)
(319 kb)
Process
Compaction
Single Compaction to Achieve High Density in Ferrous PM Materials in Automotive Applications
i
The continued growth of ferrous powder metallurgy in automotive applications is
dependent on the development of higher density and improved dynamic properties.
New powder metallurgy applications also must be cost effective through the continued use of the process's, net shape forming capabilities and a reduced number of manufacturing steps. The processes utilized to manufacture some of these new parts also must provide the ability to produce thin walled parts with complex geometries. The use of the warm compaction process (ANCORDENSE™) will be shown to develop high density levels with a single compaction process. The process also provides increased green strength and reduced ejection forces. The dependence of mechanical properties on density will be demonstrated. An example of a potential application of the warm compaction technology is an output shaft. The capability of manufacturing this part with the warm compaction process is outlined and compared with the same part made by the double press/double sinter (DPDS) process. Part density and performance from both processes are compared. (1996)
(319 kb)
Materials
Alloy Method
Properties of Several Ancordense Processed High Performance Materials
i
The effect of powder and compaction temperature on the ANCORDENSE warm compaction system is evaluated. Detailed property analysis is presented on several warm compacted high performance materials systems. Properties evaluated include density, tensile, and impact performance. A detailed assessment of the microstructure resulting from various alloy compositions and processing techniques is performed. The materials involved in the tests were conventional and high temperature sintered and tested in the as sintered and heat treated condition. (1996)
(1.55 mb)
Materials
Alloys
Properties of Several Ancordense Processed High Performance Materials
i
The effect of powder and compaction temperature on the ANCORDENSE warm compaction system is evaluated. Detailed property analysis is presented on several warm compacted high performance materials systems. Properties evaluated include density, tensile, and impact performance. A detailed assessment of the microstructure resulting from various alloy compositions and processing techniques is performed. The materials involved in the tests were conventional and high temperature sintered and tested in the as sintered and heat treated condition. (1996)
(1.55 mb)
Materials
Binder-Treatment & High Density
Properties of Several Ancordense Processed High Performance Materials
i
The effect of powder and compaction temperature on the ANCORDENSE warm compaction system is evaluated. Detailed property analysis is presented on several warm compacted high performance materials systems. Properties evaluated include density, tensile, and impact performance. A detailed assessment of the microstructure resulting from various alloy compositions and processing techniques is performed. The materials involved in the tests were conventional and high temperature sintered and tested in the as sintered and heat treated condition. (1996)
(1.55 mb)
Material Properties
Mechanical Properties
Properties of Several Ancordense Processed High Performance Materials
i
The effect of powder and compaction temperature on the ANCORDENSE warm compaction system is evaluated. Detailed property analysis is presented on several warm compacted high performance materials systems. Properties evaluated include density, tensile, and impact performance. A detailed assessment of the microstructure resulting from various alloy compositions and processing techniques is performed. The materials involved in the tests were conventional and high temperature sintered and tested in the as sintered and heat treated condition. (1996)
(1.55 mb)
Process
Sintering
Properties of Several Ancordense Processed High Performance Materials
i
The effect of powder and compaction temperature on the ANCORDENSE warm compaction system is evaluated. Detailed property analysis is presented on several warm compacted high performance materials systems. Properties evaluated include density, tensile, and impact performance. A detailed assessment of the microstructure resulting from various alloy compositions and processing techniques is performed. The materials involved in the tests were conventional and high temperature sintered and tested in the as sintered and heat treated condition. (1996)
(1.55 mb)
Materials
Additives
Enhanced Green Strength Material System for Ferrous and Stainless PM Processing
i
Strength limitations of green powder metallurgy compacts often present fabricators with processing problems. Increased part complexity, process automation and the need for reduced green scrap requires the P/M compact to attain higher green strength. Currently, several limitations restrict the ability to increase green strength in P/M compacts. Powder characteristics, such as particle size distribution and morphology, compressibility and common lubricant systems, all pose limitations on the compact green strength. Enhanced material systems improve the green strength of ferrous-based P/M parts by a minimum of 100% relative to compacts containing admixed lubricant. Process advantages, specific test results, and side effects of high green strength systems will be discussed. (1996)
(1.90 mb)
Process
Compaction
Enhanced Green Strength Material System for Ferrous and Stainless PM Processing
i
Strength limitations of green powder metallurgy compacts often present fabricators with processing problems. Increased part complexity, process automation and the need for reduced green scrap requires the P/M compact to attain higher green strength. Currently, several limitations restrict the ability to increase green strength in P/M compacts. Powder characteristics, such as particle size distribution and morphology, compressibility and common lubricant systems, all pose limitations on the compact green strength. Enhanced material systems improve the green strength of ferrous-based P/M parts by a minimum of 100% relative to compacts containing admixed lubricant. Process advantages, specific test results, and side effects of high green strength systems will be discussed. (1996)
(1.90 mb)
Material Properties
Green Properties
Enhanced Green Strength Material System for Ferrous and Stainless PM Processing
i
Strength limitations of green powder metallurgy compacts often present fabricators with processing problems. Increased part complexity, process automation and the need for reduced green scrap requires the P/M compact to attain higher green strength. Currently, several limitations restrict the ability to increase green strength in P/M compacts. Powder characteristics, such as particle size distribution and morphology, compressibility and common lubricant systems, all pose limitations on the compact green strength. Enhanced material systems improve the green strength of ferrous-based P/M parts by a minimum of 100% relative to compacts containing admixed lubricant. Process advantages, specific test results, and side effects of high green strength systems will be discussed. (1996)
(1.90 mb)
Material Properties
Powder Properties
Enhanced Green Strength Material System for Ferrous and Stainless PM Processing
i
Strength limitations of green powder metallurgy compacts often present fabricators with processing problems. Increased part complexity, process automation and the need for reduced green scrap requires the P/M compact to attain higher green strength. Currently, several limitations restrict the ability to increase green strength in P/M compacts. Powder characteristics, such as particle size distribution and morphology, compressibility and common lubricant systems, all pose limitations on the compact green strength. Enhanced material systems improve the green strength of ferrous-based P/M parts by a minimum of 100% relative to compacts containing admixed lubricant. Process advantages, specific test results, and side effects of high green strength systems will be discussed. (1996)
(1.90 mb)
Materials
Additives
Continuing Improvements in Binder Treatment Technology
i
The binder-lubricant concept in which the binder acts to lubricate as well as to bond is introduced. The binder treatment effects on premix properties of an ordinary binder versus one with lubricating properties are compared. It is shown that the lubricating binder is superior in terms of its effects on compressibility and die ejection forces. Otherwise, it is shown to be similar to the ordinary binder in suppressing dusting and
segregation, and improving powder flow. (1996)
(44 kb)
Materials
Binder-Treatment & High Density
Continuing Improvements in Binder Treatment Technology
i
The binder-lubricant concept in which the binder acts to lubricate as well as to bond is introduced. The binder treatment effects on premix properties of an ordinary binder versus one with lubricating properties are compared. It is shown that the lubricating binder is superior in terms of its effects on compressibility and die ejection forces. Otherwise, it is shown to be similar to the ordinary binder in suppressing dusting and
segregation, and improving powder flow. (1996)
(44 kb)
Process
Compaction
Continuing Improvements in Binder Treatment Technology
i
The binder-lubricant concept in which the binder acts to lubricate as well as to bond is introduced. The binder treatment effects on premix properties of an ordinary binder versus one with lubricating properties are compared. It is shown that the lubricating binder is superior in terms of its effects on compressibility and die ejection forces. Otherwise, it is shown to be similar to the ordinary binder in suppressing dusting and
segregation, and improving powder flow. (1996)
(44 kb)
Material Properties
Green Properties
Continuing Improvements in Binder Treatment Technology
i
The binder-lubricant concept in which the binder acts to lubricate as well as to bond is introduced. The binder treatment effects on premix properties of an ordinary binder versus one with lubricating properties are compared. It is shown that the lubricating binder is superior in terms of its effects on compressibility and die ejection forces. Otherwise, it is shown to be similar to the ordinary binder in suppressing dusting and
segregation, and improving powder flow. (1996)
(44 kb)
Material Properties
Powder Properties
Continuing Improvements in Binder Treatment Technology
i
The binder-lubricant concept in which the binder acts to lubricate as well as to bond is introduced. The binder treatment effects on premix properties of an ordinary binder versus one with lubricating properties are compared. It is shown that the lubricating binder is superior in terms of its effects on compressibility and die ejection forces. Otherwise, it is shown to be similar to the ordinary binder in suppressing dusting and
segregation, and improving powder flow. (1996)
(44 kb)
Materials
Additives
Machinability of PM Steels
i
This paper will examine the potential to improve the machinability of sintered P/M steels by the addition of freemachining agents. Testing will examine the effects of freemachining agents upon the sintered properties and machinability in drilling of commercial P/M steels, including FC-0208 or FN-0205. (1995)
(876 kb)
Material Properties
Alloy cleanliness
Machinability of PM Steels
i
This paper will examine the potential to improve the machinability of sintered P/M steels by the addition of freemachining agents. Testing will examine the effects of freemachining agents upon the sintered properties and machinability in drilling of commercial P/M steels, including FC-0208 or FN-0205. (1995)
(876 kb)
Process
Secondary Processing
Machinability of PM Steels
i
This paper will examine the potential to improve the machinability of sintered P/M steels by the addition of freemachining agents. Testing will examine the effects of freemachining agents upon the sintered properties and machinability in drilling of commercial P/M steels, including FC-0208 or FN-0205. (1995)
(876 kb)
Materials
Binder-Treatment & High Density
Machinability Evaluation of Selected High Green Strength PM Materials
i
P/M parts generally require machining methods and specific tools designed to address the inherent porosity of the finished part. The composition and microstructure of sintered parts often causes machining problems and requires additives to enhance machinability. Currently, conventionally produced ferrous P/M parts have an average green strength of approximately 1500-psi. Recent technological advances with organic binders and lubricants, combined with improved compaction technology, have made it possible to produce P/M parts with enhanced green strengths. Enhanced green strength makes it possible to machine materials in the green state, thereby reducing manufacturing time and production costs. This paper examines green drilling by applying several machinability and material evaluation methods. (1995)
(1.46 mb)
Material Properties
Green Properties
Machinability Evaluation of Selected High Green Strength PM Materials
i
P/M parts generally require machining methods and specific tools designed to address the inherent porosity of the finished part. The composition and microstructure of sintered parts often causes machining problems and requires additives to enhance machinability. Currently, conventionally produced ferrous P/M parts have an average green strength of approximately 1500-psi. Recent technological advances with organic binders and lubricants, combined with improved compaction technology, have made it possible to produce P/M parts with enhanced green strengths. Enhanced green strength makes it possible to machine materials in the green state, thereby reducing manufacturing time and production costs. This paper examines green drilling by applying several machinability and material evaluation methods. (1995)
(1.46 mb)
Process
Secondary Processing
Machinability Evaluation of Selected High Green Strength PM Materials
i
P/M parts generally require machining methods and specific tools designed to address the inherent porosity of the finished part. The composition and microstructure of sintered parts often causes machining problems and requires additives to enhance machinability. Currently, conventionally produced ferrous P/M parts have an average green strength of approximately 1500-psi. Recent technological advances with organic binders and lubricants, combined with improved compaction technology, have made it possible to produce P/M parts with enhanced green strengths. Enhanced green strength makes it possible to machine materials in the green state, thereby reducing manufacturing time and production costs. This paper examines green drilling by applying several machinability and material evaluation methods. (1995)
(1.46 mb)
Materials
Alloy Method
Properties of Diffusion Bonded Alloys Processed To High Densities
i
Diffusion bonded alloys have been shown to exhibit excellent properties. Recent advancements in compaction technology have allowed these materials to reach green density levels of over 7.3 g/cm3 in a single compaction process. Various capabilities of this new compaction system will be demonstrated utilizing diffusion bonded alloys. Properties of several diffusion bonded materials will be investigated at these high density levels. A variety of processing techniques will be utilized including high temperature sintering and heat treatment to demonstrate the flexibility of these materials. (1995)
(395 kb)
Materials
Binder-Treatment & High Density
Properties of Diffusion Bonded Alloys Processed To High Densities
i
Diffusion bonded alloys have been shown to exhibit excellent properties. Recent advancements in compaction technology have allowed these materials to reach green density levels of over 7.3 g/cm3 in a single compaction process. Various capabilities of this new compaction system will be demonstrated utilizing diffusion bonded alloys. Properties of several diffusion bonded materials will be investigated at these high density levels. A variety of processing techniques will be utilized including high temperature sintering and heat treatment to demonstrate the flexibility of these materials. (1995)
(395 kb)
Process
Compaction
Properties of Diffusion Bonded Alloys Processed To High Densities
i
Diffusion bonded alloys have been shown to exhibit excellent properties. Recent advancements in compaction technology have allowed these materials to reach green density levels of over 7.3 g/cm3 in a single compaction process. Various capabilities of this new compaction system will be demonstrated utilizing diffusion bonded alloys. Properties of several diffusion bonded materials will be investigated at these high density levels. A variety of processing techniques will be utilized including high temperature sintering and heat treatment to demonstrate the flexibility of these materials. (1995)
(395 kb)
Material Properties
Green Properties
Properties of Diffusion Bonded Alloys Processed To High Densities
i
Diffusion bonded alloys have been shown to exhibit excellent properties. Recent advancements in compaction technology have allowed these materials to reach green density levels of over 7.3 g/cm3 in a single compaction process. Various capabilities of this new compaction system will be demonstrated utilizing diffusion bonded alloys. Properties of several diffusion bonded materials will be investigated at these high density levels. A variety of processing techniques will be utilized including high temperature sintering and heat treatment to demonstrate the flexibility of these materials. (1995)
(395 kb)
Material Properties
Mechanical Properties
Properties of Diffusion Bonded Alloys Processed To High Densities
i
Diffusion bonded alloys have been shown to exhibit excellent properties. Recent advancements in compaction technology have allowed these materials to reach green density levels of over 7.3 g/cm3 in a single compaction process. Various capabilities of this new compaction system will be demonstrated utilizing diffusion bonded alloys. Properties of several diffusion bonded materials will be investigated at these high density levels. A variety of processing techniques will be utilized including high temperature sintering and heat treatment to demonstrate the flexibility of these materials. (1995)
(395 kb)
Process
Sintering
Properties of Diffusion Bonded Alloys Processed To High Densities
i
Diffusion bonded alloys have been shown to exhibit excellent properties. Recent advancements in compaction technology have allowed these materials to reach green density levels of over 7.3 g/cm3 in a single compaction process. Various capabilities of this new compaction system will be demonstrated utilizing diffusion bonded alloys. Properties of several diffusion bonded materials will be investigated at these high density levels. A variety of processing techniques will be utilized including high temperature sintering and heat treatment to demonstrate the flexibility of these materials. (1995)
(395 kb)
Materials
Binder-Treatment & High Density
Advanced Properties of High Density Ferrous Powder Metallurgy Materials
i
The introduction of the ANCORDENSE system has provided significantly higher density levels than previously possible in a single press/single sinter operation. This paper will explore the role that higher density has on mechanical properties. Various properties will be evaluated, including transverse rupture strength, tensile strength, and impact.
Additionally, the effect of other processes, such as high temperature sintering and heat treatment, will be addressed. (1995)
(1.47 mb)
Material Properties
Green Properties
Advanced Properties of High Density Ferrous Powder Metallurgy Materials
i
The introduction of the ANCORDENSE system has provided significantly higher density levels than previously possible in a single press/single sinter operation. This paper will explore the role that higher density has on mechanical properties. Various properties will be evaluated, including transverse rupture strength, tensile strength, and impact.
Additionally, the effect of other processes, such as high temperature sintering and heat treatment, will be addressed. (1995)
(1.47 mb)
Process
Secondary Processing
Advanced Properties of High Density Ferrous Powder Metallurgy Materials
i
The introduction of the ANCORDENSE system has provided significantly higher density levels than previously possible in a single press/single sinter operation. This paper will explore the role that higher density has on mechanical properties. Various properties will be evaluated, including transverse rupture strength, tensile strength, and impact.
Additionally, the effect of other processes, such as high temperature sintering and heat treatment, will be addressed. (1995)
(1.47 mb)
Process
Sintering
Advanced Properties of High Density Ferrous Powder Metallurgy Materials
i
The introduction of the ANCORDENSE system has provided significantly higher density levels than previously possible in a single press/single sinter operation. This paper will explore the role that higher density has on mechanical properties. Various properties will be evaluated, including transverse rupture strength, tensile strength, and impact.
Additionally, the effect of other processes, such as high temperature sintering and heat treatment, will be addressed. (1995)
(1.47 mb)
Materials
Binder-Treatment & High Density
An Investigation into the Effects of Processing Methods on the Mechanical Characteristics of High Performance Ferrous
i
The mechanical properties of high performance ferrous P/M materials are influenced by the material composition and processing method. This paper investigates the effects of the ANCORDENSE™ process, a new, high density, single compaction
method, on the mechanical properties of Distaloy® 4800A based materials. The results of this study are discussed with a comparison to the mechanical properties for the same materials developed through single-pressed and double-pressed, doublesintered processing methods. In addition, a case study is performed on a component produced via the ANCORDENSE method. (1995)
(587 kb)
Material Properties
Mechanical Properties
An Investigation into the Effects of Processing Methods on the Mechanical Characteristics of High Performance Ferrous
i
The mechanical properties of high performance ferrous P/M materials are influenced by the material composition and processing method. This paper investigates the effects of the ANCORDENSE™ process, a new, high density, single compaction
method, on the mechanical properties of Distaloy® 4800A based materials. The results of this study are discussed with a comparison to the mechanical properties for the same materials developed through single-pressed and double-pressed, doublesintered processing methods. In addition, a case study is performed on a component produced via the ANCORDENSE method. (1995)
(587 kb)
Process
Sintering
An Investigation into the Effects of Processing Methods on the Mechanical Characteristics of High Performance Ferrous
i
The mechanical properties of high performance ferrous P/M materials are influenced by the material composition and processing method. This paper investigates the effects of the ANCORDENSE™ process, a new, high density, single compaction
method, on the mechanical properties of Distaloy® 4800A based materials. The results of this study are discussed with a comparison to the mechanical properties for the same materials developed through single-pressed and double-pressed, doublesintered processing methods. In addition, a case study is performed on a component produced via the ANCORDENSE method. (1995)
(587 kb)
Material Properties
Test Methods
An Investigation into the Effects of Processing Methods on the Mechanical Characteristics of High Performance Ferrous
i
The mechanical properties of high performance ferrous P/M materials are influenced by the material composition and processing method. This paper investigates the effects of the ANCORDENSE™ process, a new, high density, single compaction
method, on the mechanical properties of Distaloy® 4800A based materials. The results of this study are discussed with a comparison to the mechanical properties for the same materials developed through single-pressed and double-pressed, doublesintered processing methods. In addition, a case study is performed on a component produced via the ANCORDENSE method. (1995)
(587 kb)
Materials
Binder-Treatment & High Density
Recent Developments in Ferrous Powder Metallurgy Alloys
i
A systems approach to engineered ferrous powder metallurgy (P/M) materials is described. The approach encompasses the use of high compressible, high performance powders in premixes produced using proprietary mixing technology that employs patented binders. To ensure that an appropriate microstructure is achieved to suit the functional requirements of a particular application, alloys are formulated based on knowledge of the compaction and sintering cycle that will be used to
make the P/M parts. These premixes have improved flow and die filling characteristics that result in greater consistency throughout the entire P/M part manufacturing process. In addition, the use of binder treated premixes leads to reduced dusting and segregation of alloy additions. Binder treated premixes produced using high compressible, prealloyed molybdenum steel powders are shown to be particularly well suited for quench-hardening, sinter-hardening, and high temperature sintering. They also form the basis for a series of chromium, manganese, and chrome-manganese P/M Steels. The systems approach will be augmented during 1994 by the introduction of new material and process technology that enables part densities of 7.3 to 7.5 g/cm3 to be achieved through single compaction processing. (1994)
(339 kb)
Process
Compaction
Recent Developments in Ferrous Powder Metallurgy Alloys
i
A systems approach to engineered ferrous powder metallurgy (P/M) materials is described. The approach encompasses the use of high compressible, high performance powders in premixes produced using proprietary mixing technology that employs patented binders. To ensure that an appropriate microstructure is achieved to suit the functional requirements of a particular application, alloys are formulated based on knowledge of the compaction and sintering cycle that will be used to
make the P/M parts. These premixes have improved flow and die filling characteristics that result in greater consistency throughout the entire P/M part manufacturing process. In addition, the use of binder treated premixes leads to reduced dusting and segregation of alloy additions. Binder treated premixes produced using high compressible, prealloyed molybdenum steel powders are shown to be particularly well suited for quench-hardening, sinter-hardening, and high temperature sintering. They also form the basis for a series of chromium, manganese, and chrome-manganese P/M Steels. The systems approach will be augmented during 1994 by the introduction of new material and process technology that enables part densities of 7.3 to 7.5 g/cm3 to be achieved through single compaction processing. (1994)
(339 kb)
Process
Secondary Processing
Laser Welding PM for Automotive Applications
i
The ability to laser weld automotive components is a determining factor in converting the currently specified wrought or cast materials to powder metallurgy (P/M) parts for various applications. Material selection, process conditions and joint design are known to have a significant influence when fusion welding P/M components. Welding trials were conducted to determine the appropriate laser parameters for several P/M grades at various density levels. Bead-on-plate, overlap and butt joint designs were attempted, primarily without filler metal additions. (1994)
(690 kb)
Materials
Additives
High Density Processing of Cr-Mn PM Steels
i
The use of chromium and manganese as alloying elements in P/M steels offers several potential advantages over copper and nickel that are used in conventional P/M alloy steels. The paper will illustrate how the principles used to improve the hardenability
and performance of wrought steels can be applied to P/M chromium and manganese alloy steels using a systems approach. The use of chromium-manganese for P/M applications was made possible by binder-treated premix technology of a highly compressible prealloyed low alloy base material. The flexibility of alloy design will be illustrated by examples of through hardening, high strength low alloy steels. (1994)
(638 kb)
Materials
Alloys
High Density Processing of Cr-Mn PM Steels
i
The use of chromium and manganese as alloying elements in P/M steels offers several potential advantages over copper and nickel that are used in conventional P/M alloy steels. The paper will illustrate how the principles used to improve the hardenability
and performance of wrought steels can be applied to P/M chromium and manganese alloy steels using a systems approach. The use of chromium-manganese for P/M applications was made possible by binder-treated premix technology of a highly compressible prealloyed low alloy base material. The flexibility of alloy design will be illustrated by examples of through hardening, high strength low alloy steels. (1994)
(638 kb)
Materials
Binder-Treatment & High Density
High Density Processing of Cr-Mn PM Steels
i
The use of chromium and manganese as alloying elements in P/M steels offers several potential advantages over copper and nickel that are used in conventional P/M alloy steels. The paper will illustrate how the principles used to improve the hardenability
and performance of wrought steels can be applied to P/M chromium and manganese alloy steels using a systems approach. The use of chromium-manganese for P/M applications was made possible by binder-treated premix technology of a highly compressible prealloyed low alloy base material. The flexibility of alloy design will be illustrated by examples of through hardening, high strength low alloy steels. (1994)
(638 kb)
Material Properties
Mechanical Properties
High Density Processing of Cr-Mn PM Steels
i
The use of chromium and manganese as alloying elements in P/M steels offers several potential advantages over copper and nickel that are used in conventional P/M alloy steels. The paper will illustrate how the principles used to improve the hardenability
and performance of wrought steels can be applied to P/M chromium and manganese alloy steels using a systems approach. The use of chromium-manganese for P/M applications was made possible by binder-treated premix technology of a highly compressible prealloyed low alloy base material. The flexibility of alloy design will be illustrated by examples of through hardening, high strength low alloy steels. (1994)
(638 kb)
Materials
Alloys
High Density Processing of High Performance Ferrous Materials
i
Density is an predominant factor in the performance of powder metallurgy components. Methods such as double press/double sinter, copper infiltration and powder forging have been employed to provide higher densities than traditional single press and sinter operations; however, their widespread use is constrained by cost and geometry considerations. A commercially proven method for obtaining single
compaction/single sinter densities in the 7.25 to 7.55 g/cm3 range by means of the patented ANCORDENSE™ technology is introduced. Conventional compaction pressures and sintering temperatures, typically not exceeding 50 tsi or 2300°F,
respectively, are utilized. Resulting properties for several high performance materials are presented. Test results indicate that the ANCORDENSE process is a cost
effective method of providing high density parts with outstanding physical properties. The process is shown to be applicable to a wide variety of high performance materials. Additionally, significant improvements in green strength and ejection forces
are realized. (1994)
(472 kb)
Materials
Binder-Treatment & High Density
High Density Processing of High Performance Ferrous Materials
i
Density is an predominant factor in the performance of powder metallurgy components. Methods such as double press/double sinter, copper infiltration and powder forging have been employed to provide higher densities than traditional single press and sinter operations; however, their widespread use is constrained by cost and geometry considerations. A commercially proven method for obtaining single
compaction/single sinter densities in the 7.25 to 7.55 g/cm3 range by means of the patented ANCORDENSE™ technology is introduced. Conventional compaction pressures and sintering temperatures, typically not exceeding 50 tsi or 2300°F,
respectively, are utilized. Resulting properties for several high performance materials are presented. Test results indicate that the ANCORDENSE process is a cost
effective method of providing high density parts with outstanding physical properties. The process is shown to be applicable to a wide variety of high performance materials. Additionally, significant improvements in green strength and ejection forces
are realized. (1994)
(472 kb)
Process
Compaction
High Density Processing of High Performance Ferrous Materials
i
Density is an predominant factor in the performance of powder metallurgy components. Methods such as double press/double sinter, copper infiltration and powder forging have been employed to provide higher densities than traditional single press and sinter operations; however, their widespread use is constrained by cost and geometry considerations. A commercially proven method for obtaining single
compaction/single sinter densities in the 7.25 to 7.55 g/cm3 range by means of the patented ANCORDENSE™ technology is introduced. Conventional compaction pressures and sintering temperatures, typically not exceeding 50 tsi or 2300°F,
respectively, are utilized. Resulting properties for several high performance materials are presented. Test results indicate that the ANCORDENSE process is a cost
effective method of providing high density parts with outstanding physical properties. The process is shown to be applicable to a wide variety of high performance materials. Additionally, significant improvements in green strength and ejection forces
are realized. (1994)
(472 kb)
Material Properties
Green Properties
High Density Processing of High Performance Ferrous Materials
i
Density is an predominant factor in the performance of powder metallurgy components. Methods such as double press/double sinter, copper infiltration and powder forging have been employed to provide higher densities than traditional single press and sinter operations; however, their widespread use is constrained by cost and geometry considerations. A commercially proven method for obtaining single
compaction/single sinter densities in the 7.25 to 7.55 g/cm3 range by means of the patented ANCORDENSE™ technology is introduced. Conventional compaction pressures and sintering temperatures, typically not exceeding 50 tsi or 2300°F,
respectively, are utilized. Resulting properties for several high performance materials are presented. Test results indicate that the ANCORDENSE process is a cost
effective method of providing high density parts with outstanding physical properties. The process is shown to be applicable to a wide variety of high performance materials. Additionally, significant improvements in green strength and ejection forces
are realized. (1994)
(472 kb)
Materials
Binder-Treatment & High Density
Properties of High Density Ferrous PM Materials a Study of Various Processes
i
Several methods of achieving higher density in ferrous P/M parts are possible. Double press/double sinter allows densities in excess of 7.3 g/cm3 but is limited by cost and geometry considerations. A new method of single processing high performance materials is evaluated and compared to other methods of processing. The comparison is performed utilizing Ancorsteel 85HP and Distaloy 4800A base materials. Various green and sintered properties are evaluated including; green strength, transverse rupture strength, tensile properties and impact values. The data clearly demonstrates that the patented (1) ANCORDENSE™* process offers performance comparable to double press/double sinter processing. Green density values of approximately 98.5% of the pore free density limit are achieved with a single compaction step. (1994)
(520 kb)
Process
Compaction
Properties of High Density Ferrous PM Materials a Study of Various Processes
i
Several methods of achieving higher density in ferrous P/M parts are possible. Double press/double sinter allows densities in excess of 7.3 g/cm3 but is limited by cost and geometry considerations. A new method of single processing high performance materials is evaluated and compared to other methods of processing. The comparison is performed utilizing Ancorsteel 85HP and Distaloy 4800A base materials. Various green and sintered properties are evaluated including; green strength, transverse rupture strength, tensile properties and impact values. The data clearly demonstrates that the patented (1) ANCORDENSE™* process offers performance comparable to double press/double sinter processing. Green density values of approximately 98.5% of the pore free density limit are achieved with a single compaction step. (1994)
(520 kb)
Material Properties
Green Properties
Properties of High Density Ferrous PM Materials a Study of Various Processes
i
Several methods of achieving higher density in ferrous P/M parts are possible. Double press/double sinter allows densities in excess of 7.3 g/cm3 but is limited by cost and geometry considerations. A new method of single processing high performance materials is evaluated and compared to other methods of processing. The comparison is performed utilizing Ancorsteel 85HP and Distaloy 4800A base materials. Various green and sintered properties are evaluated including; green strength, transverse rupture strength, tensile properties and impact values. The data clearly demonstrates that the patented (1) ANCORDENSE™* process offers performance comparable to double press/double sinter processing. Green density values of approximately 98.5% of the pore free density limit are achieved with a single compaction step. (1994)
(520 kb)
Process
Powder production
Continuous Improvements in Atomized Powders through Team-Oriented Problem Solving
i
A “Total Quality System” approach at Hoeganaes allows all employees to participate in achieving the organization's quality goals. The various phases of the quality system from product control, SPC, process documentation, team development, and team oriented process development are reviewed. One example of team-oriented process improvement will be demonstrated using the improvements achieved in the
microcleanliness of atomized products. (1994)
(283 kb)
Material Properties
Alloy cleanliness
Continuous Improvements in Atomized Powders through Team-Oriented Problem Solving
i
A “Total Quality System” approach at Hoeganaes allows all employees to participate in achieving the organization's quality goals. The various phases of the quality system from product control, SPC, process documentation, team development, and team oriented process development are reviewed. One example of team-oriented process improvement will be demonstrated using the improvements achieved in the
microcleanliness of atomized products. (1994)
(283 kb)
Material Properties
Mechanical Properties
Continuous Improvements in Atomized Powders through Team-Oriented Problem Solving
i
A “Total Quality System” approach at Hoeganaes allows all employees to participate in achieving the organization's quality goals. The various phases of the quality system from product control, SPC, process documentation, team development, and team oriented process development are reviewed. One example of team-oriented process improvement will be demonstrated using the improvements achieved in the
microcleanliness of atomized products. (1994)
(283 kb)
Materials
Alloys
Effects of Powder Properties and Processing On Soft Magnetic Performance of 400-Series Stainless Steel Parts
i
With the advent of growth in soft magnetic applications suitable to Powder Metallurgy, powder manufacturers parts fabricators and end users of such parts must gain a better understanding of the relationships between powders, processing and the ultimate performance of soft magnetic P/M parts. Studies have been conducted and valuable data extracted on the subjects of pure iron, iron-phosphorus, iron-silicon and prealloyed iron-nickel alloys as they relate to magnetic properties. With the identification of applications requiring corrosion resistance as well as mechanical and magnetic properties, including the Anti-lock Brake System (ABS) tone wheel, industry is investigating ferritic stainless steel solutions. This study represents an effort to provide some initial answers to questions regarding the "real world" capability of P/M production of high quality, ferritic stainless steel parts that exhibit excellent magnetic properties. (1993)
(699 kb)
Process
Sintering
Effects of Powder Properties and Processing On Soft Magnetic Performance of 400-Series Stainless Steel Parts
i
With the advent of growth in soft magnetic applications suitable to Powder Metallurgy, powder manufacturers parts fabricators and end users of such parts must gain a better understanding of the relationships between powders, processing and the ultimate performance of soft magnetic P/M parts. Studies have been conducted and valuable data extracted on the subjects of pure iron, iron-phosphorus, iron-silicon and prealloyed iron-nickel alloys as they relate to magnetic properties. With the identification of applications requiring corrosion resistance as well as mechanical and magnetic properties, including the Anti-lock Brake System (ABS) tone wheel, industry is investigating ferritic stainless steel solutions. This study represents an effort to provide some initial answers to questions regarding the "real world" capability of P/M production of high quality, ferritic stainless steel parts that exhibit excellent magnetic properties. (1993)
(699 kb)
Materials
Alloys
Fusion Welding PM Components for Automotive Applications
i
The paper identifies welding methods that are most often used to join P/M automotive components. Various weld procedures associated with the different methods are discussed. Examples are presented along with appropriate process information. A more detailed application development involves Gas Tungsten Arc
welding a stainless P/M exhaust bushing to a wrought stainless steel tube. (1993)
(431 kb)
Process
Secondary Processing
Fusion Welding PM Components for Automotive Applications
i
The paper identifies welding methods that are most often used to join P/M automotive components. Various weld procedures associated with the different methods are discussed. Examples are presented along with appropriate process information. A more detailed application development involves Gas Tungsten Arc
welding a stainless P/M exhaust bushing to a wrought stainless steel tube. (1993)
(431 kb)
Material Properties
Test Methods
Fusion Welding PM Components for Automotive Applications
i
The paper identifies welding methods that are most often used to join P/M automotive components. Various weld procedures associated with the different methods are discussed. Examples are presented along with appropriate process information. A more detailed application development involves Gas Tungsten Arc
welding a stainless P/M exhaust bushing to a wrought stainless steel tube. (1993)
(431 kb)
Material Properties
Hardenability
Properties of Heat Treated PM Alloy Steels
i
Further development of ferrous P/M technology into highly stressed applications will require the development of P/M steels with mechanical properties approaching those of cast or wrought products. The P/M process offers many routes to improve mechanical properties through alloy design, increased density and high temperature sintering. The paper will present the results of a study into the effects of density and composition upon the microstructure and properties of quenched and tempered P/M alloy steels. (1993)
(2.18 mb)
Material Properties
Mechanical Properties
Properties of Heat Treated PM Alloy Steels
i
Further development of ferrous P/M technology into highly stressed applications will require the development of P/M steels with mechanical properties approaching those of cast or wrought products. The P/M process offers many routes to improve mechanical properties through alloy design, increased density and high temperature sintering. The paper will present the results of a study into the effects of density and composition upon the microstructure and properties of quenched and tempered P/M alloy steels. (1993)
(2.18 mb)
Process
Secondary Processing
Properties of Heat Treated PM Alloy Steels
i
Further development of ferrous P/M technology into highly stressed applications will require the development of P/M steels with mechanical properties approaching those of cast or wrought products. The P/M process offers many routes to improve mechanical properties through alloy design, increased density and high temperature sintering. The paper will present the results of a study into the effects of density and composition upon the microstructure and properties of quenched and tempered P/M alloy steels. (1993)
(2.18 mb)
Material Properties
Test Methods
Properties of Heat Treated PM Alloy Steels
i
Further development of ferrous P/M technology into highly stressed applications will require the development of P/M steels with mechanical properties approaching those of cast or wrought products. The P/M process offers many routes to improve mechanical properties through alloy design, increased density and high temperature sintering. The paper will present the results of a study into the effects of density and composition upon the microstructure and properties of quenched and tempered P/M alloy steels. (1993)
(2.18 mb)
Materials
Binder-Treatment & High Density
Dust and Segregation-Free Powders for Flexible PM Processing
i
During the past few years, there has been increasing demand placed on P/M parts
producers to improve density uniformity, weight variation, alloy homogeneity and
dimensional control. Enhanced flow and die fill characteristics are also required to
improve productivity and reduce the percentage of green scrap. The ANCORBOND® process developed by Hoeganaes has satisfied many of these requirements by bonding the alloy additives and fines to the base iron particles. Increased concerns regarding the inability to retrofit higher apparent density premixes to existing tool sets, a slight loss of compressibility and the desire to reduce the total organic content for improved burnout response led to further improvements in the bonding process. Several factors that contribute to the performance and greater flexibility of binder-treated mixes compared with regular mixes will be discussed in this paper. (1993)
(298 kb)
Process
Compaction
Dust and Segregation-Free Powders for Flexible PM Processing
i
During the past few years, there has been increasing demand placed on P/M parts
producers to improve density uniformity, weight variation, alloy homogeneity and
dimensional control. Enhanced flow and die fill characteristics are also required to
improve productivity and reduce the percentage of green scrap. The ANCORBOND® process developed by Hoeganaes has satisfied many of these requirements by bonding the alloy additives and fines to the base iron particles. Increased concerns regarding the inability to retrofit higher apparent density premixes to existing tool sets, a slight loss of compressibility and the desire to reduce the total organic content for improved burnout response led to further improvements in the bonding process. Several factors that contribute to the performance and greater flexibility of binder-treated mixes compared with regular mixes will be discussed in this paper. (1993)
(298 kb)
Material Properties
Powder Properties
Dust and Segregation-Free Powders for Flexible PM Processing
i
During the past few years, there has been increasing demand placed on P/M parts
producers to improve density uniformity, weight variation, alloy homogeneity and
dimensional control. Enhanced flow and die fill characteristics are also required to
improve productivity and reduce the percentage of green scrap. The ANCORBOND® process developed by Hoeganaes has satisfied many of these requirements by bonding the alloy additives and fines to the base iron particles. Increased concerns regarding the inability to retrofit higher apparent density premixes to existing tool sets, a slight loss of compressibility and the desire to reduce the total organic content for improved burnout response led to further improvements in the bonding process. Several factors that contribute to the performance and greater flexibility of binder-treated mixes compared with regular mixes will be discussed in this paper. (1993)
(298 kb)
Materials
Additives
Surface-Hardenable Heat Treated PM Steels
i
The addition of fine particles (< 20μm) of high-carbon ferroalloys to the high compressible prealloy powders, Ancorsteel® 85 HP and Ancorsteel 150 HP, has been shown to be a practical way of producing ferrous low-alloy steels containing
chromium and manganese. Increased sintering temperatures improved the mechanical
properties of the materials and the effect was particularly noticeable at 2350°F.
The ferroalloy additions significantly enhanced the hardenability of the base low-alloys. Materials based on the low-alloy powder containing 1.5% molybdenum were more hardenable than those based on the 0.85% molybdenum alloy. These materials are well suited for plasma nitriding and should find use in gears and cams that require a hard wear-resistant surface coupled with a strong, tough core. (1992)
(1.17 mb)
Materials
Alloys
Surface-Hardenable Heat Treated PM Steels
i
The addition of fine particles (< 20μm) of high-carbon ferroalloys to the high compressible prealloy powders, Ancorsteel® 85 HP and Ancorsteel 150 HP, has been shown to be a practical way of producing ferrous low-alloy steels containing
chromium and manganese. Increased sintering temperatures improved the mechanical
properties of the materials and the effect was particularly noticeable at 2350°F.
The ferroalloy additions significantly enhanced the hardenability of the base low-alloys. Materials based on the low-alloy powder containing 1.5% molybdenum were more hardenable than those based on the 0.85% molybdenum alloy. These materials are well suited for plasma nitriding and should find use in gears and cams that require a hard wear-resistant surface coupled with a strong, tough core. (1992)
(1.17 mb)
Material Properties
Hardenability
Surface-Hardenable Heat Treated PM Steels
i
The addition of fine particles (< 20μm) of high-carbon ferroalloys to the high compressible prealloy powders, Ancorsteel® 85 HP and Ancorsteel 150 HP, has been shown to be a practical way of producing ferrous low-alloy steels containing
chromium and manganese. Increased sintering temperatures improved the mechanical
properties of the materials and the effect was particularly noticeable at 2350°F.
The ferroalloy additions significantly enhanced the hardenability of the base low-alloys. Materials based on the low-alloy powder containing 1.5% molybdenum were more hardenable than those based on the 0.85% molybdenum alloy. These materials are well suited for plasma nitriding and should find use in gears and cams that require a hard wear-resistant surface coupled with a strong, tough core. (1992)
(1.17 mb)
Material Properties
Mechanical Properties
Surface-Hardenable Heat Treated PM Steels
i
The addition of fine particles (< 20μm) of high-carbon ferroalloys to the high compressible prealloy powders, Ancorsteel® 85 HP and Ancorsteel 150 HP, has been shown to be a practical way of producing ferrous low-alloy steels containing
chromium and manganese. Increased sintering temperatures improved the mechanical
properties of the materials and the effect was particularly noticeable at 2350°F.
The ferroalloy additions significantly enhanced the hardenability of the base low-alloys. Materials based on the low-alloy powder containing 1.5% molybdenum were more hardenable than those based on the 0.85% molybdenum alloy. These materials are well suited for plasma nitriding and should find use in gears and cams that require a hard wear-resistant surface coupled with a strong, tough core. (1992)
(1.17 mb)
Process
Sintering
Surface-Hardenable Heat Treated PM Steels
i
The addition of fine particles (< 20μm) of high-carbon ferroalloys to the high compressible prealloy powders, Ancorsteel® 85 HP and Ancorsteel 150 HP, has been shown to be a practical way of producing ferrous low-alloy steels containing
chromium and manganese. Increased sintering temperatures improved the mechanical
properties of the materials and the effect was particularly noticeable at 2350°F.
The ferroalloy additions significantly enhanced the hardenability of the base low-alloys. Materials based on the low-alloy powder containing 1.5% molybdenum were more hardenable than those based on the 0.85% molybdenum alloy. These materials are well suited for plasma nitriding and should find use in gears and cams that require a hard wear-resistant surface coupled with a strong, tough core. (1992)
(1.17 mb)
Materials
Alloys
High Performance Ferrous PM Materials Utilizing High Temperature Sintering
i
Several new and more challenging P/M applications require materials that exhibit higher strength along with improved dynamic property characteristics. To meet these requirements, development efforts focused on material grades capable of achieving high performance properties when sintered at elevated temperature. Several elements, specifically nickel and copper, were admixed to the water atomized, prealloyed low-alloy steel powders Ancorsteel® 85 HP and 150 HP using the patented ANCORBOND® process. Tensile and impact performance of the resulting materials have been reviewed along with quantitative metallography of selected as-sintered samples. The results indicate the type and amount of each admixed element plays an important role in achieving specific characteristics. In addition, the overall performance values are greater for the single press and sinter technique used in this investigation than could previously be achieved using a double press - double sinter process. (1992)
(951 kb)
Material Properties
Mechanical Properties
High Performance Ferrous PM Materials Utilizing High Temperature Sintering
i
Several new and more challenging P/M applications require materials that exhibit higher strength along with improved dynamic property characteristics. To meet these requirements, development efforts focused on material grades capable of achieving high performance properties when sintered at elevated temperature. Several elements, specifically nickel and copper, were admixed to the water atomized, prealloyed low-alloy steel powders Ancorsteel® 85 HP and 150 HP using the patented ANCORBOND® process. Tensile and impact performance of the resulting materials have been reviewed along with quantitative metallography of selected as-sintered samples. The results indicate the type and amount of each admixed element plays an important role in achieving specific characteristics. In addition, the overall performance values are greater for the single press and sinter technique used in this investigation than could previously be achieved using a double press - double sinter process. (1992)
(951 kb)
Process
Sintering
High Performance Ferrous PM Materials Utilizing High Temperature Sintering
i
Several new and more challenging P/M applications require materials that exhibit higher strength along with improved dynamic property characteristics. To meet these requirements, development efforts focused on material grades capable of achieving high performance properties when sintered at elevated temperature. Several elements, specifically nickel and copper, were admixed to the water atomized, prealloyed low-alloy steel powders Ancorsteel® 85 HP and 150 HP using the patented ANCORBOND® process. Tensile and impact performance of the resulting materials have been reviewed along with quantitative metallography of selected as-sintered samples. The results indicate the type and amount of each admixed element plays an important role in achieving specific characteristics. In addition, the overall performance values are greater for the single press and sinter technique used in this investigation than could previously be achieved using a double press - double sinter process. (1992)
(951 kb)
Material Properties
Test Methods
High Performance Ferrous PM Materials Utilizing High Temperature Sintering
i
Several new and more challenging P/M applications require materials that exhibit higher strength along with improved dynamic property characteristics. To meet these requirements, development efforts focused on material grades capable of achieving high performance properties when sintered at elevated temperature. Several elements, specifically nickel and copper, were admixed to the water atomized, prealloyed low-alloy steel powders Ancorsteel® 85 HP and 150 HP using the patented ANCORBOND® process. Tensile and impact performance of the resulting materials have been reviewed along with quantitative metallography of selected as-sintered samples. The results indicate the type and amount of each admixed element plays an important role in achieving specific characteristics. In addition, the overall performance values are greater for the single press and sinter technique used in this investigation than could previously be achieved using a double press - double sinter process. (1992)
(951 kb)
Materials
Alloys
Effects of Processing and Materials On Soft Magnetic Performance of Powder Metallurgy Parts
i
Soft magnetic properties of P/M parts are influenced by materials and processing. This paper will review the magnetic properties of several iron-based materials along with how various processing steps influence magnetic properties. In particular, density, sintering temperature, sintering time and sintering atmosphere effects will be examined. Special attention will be paid to the influence that sintering conditions have on chemistry and the resulting effects on magnetic properties. Materials investigated in the study include pure iron and combinations of iron, phosphorus, silicon and nickel. (1992)
(400 kb)
Materials
Alloys
Sinter Hardening Low-Alloy Steels
i
The availability of prealloyed steel powders employing molybdenum as the major alloying element offers new levels of compressibility and mechanical properties.
When the prealloyed powders are combined with conventional P/M additives such as copper, nickel and graphite, it is possible to develop high strength martensitic microstructures directly from the sintering cycle. The impact and tensile properties of copper, nickel, graphite premixes based upon the prealloyed molybdenum steels are compared under controlled cooled conditions. The ability to balance tensile strength, toughness and hardness by control of alloy chemistry is illustrated. (1992)
(897 kb)
Material Properties
Mechanical Properties
Sinter Hardening Low-Alloy Steels
i
The availability of prealloyed steel powders employing molybdenum as the major alloying element offers new levels of compressibility and mechanical properties.
When the prealloyed powders are combined with conventional P/M additives such as copper, nickel and graphite, it is possible to develop high strength martensitic microstructures directly from the sintering cycle. The impact and tensile properties of copper, nickel, graphite premixes based upon the prealloyed molybdenum steels are compared under controlled cooled conditions. The ability to balance tensile strength, toughness and hardness by control of alloy chemistry is illustrated. (1992)
(897 kb)
Process
Sintering
Sinter Hardening Low-Alloy Steels
i
The availability of prealloyed steel powders employing molybdenum as the major alloying element offers new levels of compressibility and mechanical properties.
When the prealloyed powders are combined with conventional P/M additives such as copper, nickel and graphite, it is possible to develop high strength martensitic microstructures directly from the sintering cycle. The impact and tensile properties of copper, nickel, graphite premixes based upon the prealloyed molybdenum steels are compared under controlled cooled conditions. The ability to balance tensile strength, toughness and hardness by control of alloy chemistry is illustrated. (1992)
(897 kb)
Materials
Alloy Method
High Performance Ferrous PM Materials for Automotive Applications
i
The majority of automotive components (transmission, chassis, suspension, and engine) for which parts with densities up to about 7.0 g/cm3 are suitable have already been converted to P/M and there are few opportunities for growth in this
density range. In order to meet the requirements of more demanding applications there has been a trend toward higher densities through the use of infiltration, double pressing/double sintering, or powder forging (l - 4) to produce parts such as synchronizer hubs, crankshaft sprockets, chain sprockets, gerotors, steering column tilt levers, planetary gear carriers, parking gears shift levers, and connecting rods. While powder forging has been shown capable of producing parts, which are superior to wrought, or cast products process economics have limited market penetration by this technology (5). The double press and sinter route also adds process costs and is probably too expensive for other than premium applications. There is a real need for a systems approach that will permit double pressed and sintered or infiltrated performance characteristics to be achieved by means of single compaction processing. The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance
characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final product (6). (1991)
(793 kb)
Materials
Alloys
High Performance Ferrous PM Materials for Automotive Applications
i
The majority of automotive components (transmission, chassis, suspension, and engine) for which parts with densities up to about 7.0 g/cm3 are suitable have already been converted to P/M and there are few opportunities for growth in this
density range. In order to meet the requirements of more demanding applications there has been a trend toward higher densities through the use of infiltration, double pressing/double sintering, or powder forging (l - 4) to produce parts such as synchronizer hubs, crankshaft sprockets, chain sprockets, gerotors, steering column tilt levers, planetary gear carriers, parking gears shift levers, and connecting rods. While powder forging has been shown capable of producing parts, which are superior to wrought, or cast products process economics have limited market penetration by this technology (5). The double press and sinter route also adds process costs and is probably too expensive for other than premium applications. There is a real need for a systems approach that will permit double pressed and sintered or infiltrated performance characteristics to be achieved by means of single compaction processing. The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance
characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final product (6). (1991)
(793 kb)
Materials
Binder-Treatment & High Density
High Performance Ferrous PM Materials for Automotive Applications
i
The majority of automotive components (transmission, chassis, suspension, and engine) for which parts with densities up to about 7.0 g/cm3 are suitable have already been converted to P/M and there are few opportunities for growth in this
density range. In order to meet the requirements of more demanding applications there has been a trend toward higher densities through the use of infiltration, double pressing/double sintering, or powder forging (l - 4) to produce parts such as synchronizer hubs, crankshaft sprockets, chain sprockets, gerotors, steering column tilt levers, planetary gear carriers, parking gears shift levers, and connecting rods. While powder forging has been shown capable of producing parts, which are superior to wrought, or cast products process economics have limited market penetration by this technology (5). The double press and sinter route also adds process costs and is probably too expensive for other than premium applications. There is a real need for a systems approach that will permit double pressed and sintered or infiltrated performance characteristics to be achieved by means of single compaction processing. The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance
characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final product (6). (1991)
(793 kb)
Process
Secondary Processing
PM Joining Processes, Materials and Techniques
i
This paper discusses the different types of joining processes most often used in conjunction with ferrous P/M material grades and components. Information from previous publications and a literature review on the various processes are highlighted. Useful design information and processing techniques are listed along with identifying the weldability of various P/M material compositions. (1991)
(517 kb)
Process
Compaction
Improved Dimensional Control and Elimination of Heat Treatment for Automotive Parts
i
The automotive industry has expressed concern about the general quality of heat treatment (austenization and quenching) and the desire to reduce or eliminate dependence upon this process whenever possible. Therefore, in a continuing effort for improvement during the past year, a process has been developed that eliminates the conventional heat treating operation for some applications. Some of these finished parts require both a high impact strength and a hardened wear resistant surface. The Charpy impact, tensile and TRS properties of a binder treated premix based on a partially alloyed powder have been evaluated utilizing a variety of processing conditions. These include various carbon contents, sintering temperatures and sintering times. Quantitative metallography was used to evaluate the pore size, pore shape and microstructural constituents present as a result of the various materials and processes. These factors were then correlated with the measured properties. (1991)
(627 kb)
Material Properties
Mechanical Properties
Improved Dimensional Control and Elimination of Heat Treatment for Automotive Parts
i
The automotive industry has expressed concern about the general quality of heat treatment (austenization and quenching) and the desire to reduce or eliminate dependence upon this process whenever possible. Therefore, in a continuing effort for improvement during the past year, a process has been developed that eliminates the conventional heat treating operation for some applications. Some of these finished parts require both a high impact strength and a hardened wear resistant surface. The Charpy impact, tensile and TRS properties of a binder treated premix based on a partially alloyed powder have been evaluated utilizing a variety of processing conditions. These include various carbon contents, sintering temperatures and sintering times. Quantitative metallography was used to evaluate the pore size, pore shape and microstructural constituents present as a result of the various materials and processes. These factors were then correlated with the measured properties. (1991)
(627 kb)
Process
Sintering
Improved Dimensional Control and Elimination of Heat Treatment for Automotive Parts
i
The automotive industry has expressed concern about the general quality of heat treatment (austenization and quenching) and the desire to reduce or eliminate dependence upon this process whenever possible. Therefore, in a continuing effort for improvement during the past year, a process has been developed that eliminates the conventional heat treating operation for some applications. Some of these finished parts require both a high impact strength and a hardened wear resistant surface. The Charpy impact, tensile and TRS properties of a binder treated premix based on a partially alloyed powder have been evaluated utilizing a variety of processing conditions. These include various carbon contents, sintering temperatures and sintering times. Quantitative metallography was used to evaluate the pore size, pore shape and microstructural constituents present as a result of the various materials and processes. These factors were then correlated with the measured properties. (1991)
(627 kb)
Materials
Alloys
Performance Characteristics of a New Sinter Hardening Low Alloy Steel
i
A martensitic microstructure can be developed in some powder metallurgy materials without the need for a secondary heat treatment operation provided the material is cooled sufficiently rapidly from the sintering temperature. These P/M materials are termed "sinter-hardening" steels. The partially alloyed powder, Distaloy 4800A, and nickel-molybdenum prealloyed steels such as Ancorsteel ® 4600V with copper additions are capable of being sinter-hardened. Ancorsteel 85 HP, a new highly compressible low-alloy powder employing molybdenum as the primary alloying element, is also capable of being sintered-hardened when copper and graphite additions are made to it. Ancorsteel 85 HP has a higher compressibility than nickel-molybdenum prealloyed powders. The effect of cooling rate has been studied on the microstructure and mechanical properties of Ancorsteel 85 HP + 2% copper + 0.9% graphite. Tensile and impact properties have been evaluated for a range of material densities and compared with those obtained with samples based on Ancorsteel 4600V. (1991)
(656 kb)
Material Properties
Mechanical Properties
Performance Characteristics of a New Sinter Hardening Low Alloy Steel
i
A martensitic microstructure can be developed in some powder metallurgy materials without the need for a secondary heat treatment operation provided the material is cooled sufficiently rapidly from the sintering temperature. These P/M materials are termed "sinter-hardening" steels. The partially alloyed powder, Distaloy 4800A, and nickel-molybdenum prealloyed steels such as Ancorsteel ® 4600V with copper additions are capable of being sinter-hardened. Ancorsteel 85 HP, a new highly compressible low-alloy powder employing molybdenum as the primary alloying element, is also capable of being sintered-hardened when copper and graphite additions are made to it. Ancorsteel 85 HP has a higher compressibility than nickel-molybdenum prealloyed powders. The effect of cooling rate has been studied on the microstructure and mechanical properties of Ancorsteel 85 HP + 2% copper + 0.9% graphite. Tensile and impact properties have been evaluated for a range of material densities and compared with those obtained with samples based on Ancorsteel 4600V. (1991)
(656 kb)
Process
Secondary Processing
Performance Characteristics of a New Sinter Hardening Low Alloy Steel
i
A martensitic microstructure can be developed in some powder metallurgy materials without the need for a secondary heat treatment operation provided the material is cooled sufficiently rapidly from the sintering temperature. These P/M materials are termed "sinter-hardening" steels. The partially alloyed powder, Distaloy 4800A, and nickel-molybdenum prealloyed steels such as Ancorsteel ® 4600V with copper additions are capable of being sinter-hardened. Ancorsteel 85 HP, a new highly compressible low-alloy powder employing molybdenum as the primary alloying element, is also capable of being sintered-hardened when copper and graphite additions are made to it. Ancorsteel 85 HP has a higher compressibility than nickel-molybdenum prealloyed powders. The effect of cooling rate has been studied on the microstructure and mechanical properties of Ancorsteel 85 HP + 2% copper + 0.9% graphite. Tensile and impact properties have been evaluated for a range of material densities and compared with those obtained with samples based on Ancorsteel 4600V. (1991)
(656 kb)
Materials
Alloy Method
Ferrous Powders - How Alloying Method Influences Sintering
i
The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final sintered product (1,2). (1991)
(1.63 mb)
Process
Compaction
Ferrous Powders - How Alloying Method Influences Sintering
i
The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final sintered product (1,2). (1991)
(1.63 mb)
Material Properties
Mechanical Properties
Ferrous Powders - How Alloying Method Influences Sintering
i
The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final sintered product (1,2). (1991)
(1.63 mb)
Process
Sintering
Ferrous Powders - How Alloying Method Influences Sintering
i
The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final sintered product (1,2). (1991)
(1.63 mb)
Material Properties
Test Methods
Ferrous Powders - How Alloying Method Influences Sintering
i
The mechanical properties of P/M materials are directly related to their microstructure and the size, distribution, and morphology of the porosity they contain. Alloying additions are made to develop specific material performance characteristics. However, the manner in which the alloys are constituted has a significant effect on the porosity and microstructure of the final sintered product (1,2). (1991)
(1.63 mb)
Materials
Alloys
Tensile, Impact and Fatigue Performance of a New Water Atomized Low-Alloy Powder - Ancorsteel 85 HP
i
A new water atomized, prealloyed powder has been developed containing 0.85% molybdenum as the alloying addition. The as-sintered and heat treated tensile, impact and fatigue performance have been determined for a range of graphite additions using both single and double pressing techniques. Results indicate that the new powder, Ancorsteel 85 HP, has a unique ability to be compacted and repressed to densities not attainable with existing prealloyed nickel-molybdenum powders. The higher densities achieved produce performance equivalent to or better than Ancorstee12000 or Ancorstee14600V using conventional single compaction techniques. However, the additional density increment achieved during repressing results in mechanical properties in excess of what is possible with the existing low-alloy steels. (1990)
(1.18 mb)
Process
Compaction
Tensile, Impact and Fatigue Performance of a New Water Atomized Low-Alloy Powder - Ancorsteel 85 HP
i
A new water atomized, prealloyed powder has been developed containing 0.85% molybdenum as the alloying addition. The as-sintered and heat treated tensile, impact and fatigue performance have been determined for a range of graphite additions using both single and double pressing techniques. Results indicate that the new powder, Ancorsteel 85 HP, has a unique ability to be compacted and repressed to densities not attainable with existing prealloyed nickel-molybdenum powders. The higher densities achieved produce performance equivalent to or better than Ancorstee12000 or Ancorstee14600V using conventional single compaction techniques. However, the additional density increment achieved during repressing results in mechanical properties in excess of what is possible with the existing low-alloy steels. (1990)
(1.18 mb)
Material Properties
Mechanical Properties
Tensile, Impact and Fatigue Performance of a New Water Atomized Low-Alloy Powder - Ancorsteel 85 HP
i
A new water atomized, prealloyed powder has been developed containing 0.85% molybdenum as the alloying addition. The as-sintered and heat treated tensile, impact and fatigue performance have been determined for a range of graphite additions using both single and double pressing techniques. Results indicate that the new powder, Ancorsteel 85 HP, has a unique ability to be compacted and repressed to densities not attainable with existing prealloyed nickel-molybdenum powders. The higher densities achieved produce performance equivalent to or better than Ancorstee12000 or Ancorstee14600V using conventional single compaction techniques. However, the additional density increment achieved during repressing results in mechanical properties in excess of what is possible with the existing low-alloy steels. (1990)
(1.18 mb)
Process
Secondary Processing
Tensile, Impact and Fatigue Performance of a New Water Atomized Low-Alloy Powder - Ancorsteel 85 HP
i
A new water atomized, prealloyed powder has been developed containing 0.85% molybdenum as the alloying addition. The as-sintered and heat treated tensile, impact and fatigue performance have been determined for a range of graphite additions using both single and double pressing techniques. Results indicate that the new powder, Ancorsteel 85 HP, has a unique ability to be compacted and repressed to densities not attainable with existing prealloyed nickel-molybdenum powders. The higher densities achieved produce performance equivalent to or better than Ancorstee12000 or Ancorstee14600V using conventional single compaction techniques. However, the additional density increment achieved during repressing results in mechanical properties in excess of what is possible with the existing low-alloy steels. (1990)
(1.18 mb)
Materials
Alloy Method
Steering Column Tilt Lever - PM Material Development
i
Automotive steering columns use a variety of levers to lock the flit mechanism in position. A new P/M material has been developed to withstand the impact and hardness performance requirements of this application. The new material is currently subjected to a brief surface carburizing and tempering treatment to impart wear resistance. The P/M part only requires honing of the pivot hole to meet the specified tolerance. Long term plans are to achieve the desired performance requirements using a modified version of the new P/M material, with a higher graphite addition, which can be used after tempering the" as-sintered" product. (1990)
(1.14 mb)
Process
Compaction
Steering Column Tilt Lever - PM Material Development
i
Automotive steering columns use a variety of levers to lock the flit mechanism in position. A new P/M material has been developed to withstand the impact and hardness performance requirements of this application. The new material is currently subjected to a brief surface carburizing and tempering treatment to impart wear resistance. The P/M part only requires honing of the pivot hole to meet the specified tolerance. Long term plans are to achieve the desired performance requirements using a modified version of the new P/M material, with a higher graphite addition, which can be used after tempering the" as-sintered" product. (1990)
(1.14 mb)
Material Properties
Mechanical Properties
Steering Column Tilt Lever - PM Material Development
i
Automotive steering columns use a variety of levers to lock the flit mechanism in position. A new P/M material has been developed to withstand the impact and hardness performance requirements of this application. The new material is currently subjected to a brief surface carburizing and tempering treatment to impart wear resistance. The P/M part only requires honing of the pivot hole to meet the specified tolerance. Long term plans are to achieve the desired performance requirements using a modified version of the new P/M material, with a higher graphite addition, which can be used after tempering the" as-sintered" product. (1990)
(1.14 mb)
Process
Secondary Processing
Steering Column Tilt Lever - PM Material Development
i
Automotive steering columns use a variety of levers to lock the flit mechanism in position. A new P/M material has been developed to withstand the impact and hardness performance requirements of this application. The new material is currently subjected to a brief surface carburizing and tempering treatment to impart wear resistance. The P/M part only requires honing of the pivot hole to meet the specified tolerance. Long term plans are to achieve the desired performance requirements using a modified version of the new P/M material, with a higher graphite addition, which can be used after tempering the" as-sintered" product. (1990)
(1.14 mb)
Material Properties
Test Methods
Steering Column Tilt Lever - PM Material Development
i
Automotive steering columns use a variety of levers to lock the flit mechanism in position. A new P/M material has been developed to withstand the impact and hardness performance requirements of this application. The new material is currently subjected to a brief surface carburizing and tempering treatment to impart wear resistance. The P/M part only requires honing of the pivot hole to meet the specified tolerance. Long term plans are to achieve the desired performance requirements using a modified version of the new P/M material, with a higher graphite addition, which can be used after tempering the" as-sintered" product. (1990)
(1.14 mb)
Materials
Binder-Treatment & High Density
Properties of Parts Made from ANCORBOND Processed Carbon-Nickel-Steel Powder Mix (FN-0208)
i
Studies were conducted to determine the effects on property variability of parts made from a bonded Ancorsteel 1000 mix containing 0.95% graphite, 2.0% nickel, 0.6% Acrawax and 0.3% zinc stearate. The part geometry studied was that of a cylindrical bushing. The treatment effects on powder properties and on several parts properties were determined. The powder properties included the traditional green and sintered properties and the graphite and nickel dusting resistance’s. The parts properties surveyed included both green and sintered properties and sintered carbon and nickel contents. Similar studies of a companion regular mix of nominally the same composition were conducted for purposes of comparison. (1989)
(273 kb)
Process
Compaction
Properties of Parts Made from ANCORBOND Processed Carbon-Nickel-Steel Powder Mix (FN-0208)
i
Studies were conducted to determine the effects on property variability of parts made from a bonded Ancorsteel 1000 mix containing 0.95% graphite, 2.0% nickel, 0.6% Acrawax and 0.3% zinc stearate. The part geometry studied was that of a cylindrical bushing. The treatment effects on powder properties and on several parts properties were determined. The powder properties included the traditional green and sintered properties and the graphite and nickel dusting resistance’s. The parts properties surveyed included both green and sintered properties and sintered carbon and nickel contents. Similar studies of a companion regular mix of nominally the same composition were conducted for purposes of comparison. (1989)
(273 kb)
Material Properties
Dimensional Behavior
Properties of Parts Made from ANCORBOND Processed Carbon-Nickel-Steel Powder Mix (FN-0208)
i
Studies were conducted to determine the effects on property variability of parts made from a bonded Ancorsteel 1000 mix containing 0.95% graphite, 2.0% nickel, 0.6% Acrawax and 0.3% zinc stearate. The part geometry studied was that of a cylindrical bushing. The treatment effects on powder properties and on several parts properties were determined. The powder properties included the traditional green and sintered properties and the graphite and nickel dusting resistance’s. The parts properties surveyed included both green and sintered properties and sintered carbon and nickel contents. Similar studies of a companion regular mix of nominally the same composition were conducted for purposes of comparison. (1989)
(273 kb)
Material Properties
Test Methods
A Review of Nondestructive Testing Methods and Their Applicability to Powder Metallurgy Processing
i
The problem of forming defects in green parts during compaction and ejection has become more prevalent as parts producers have started to use higher compaction pressures in an effort to achieve high density, high performance P/M steels. In this review, several nondestructive inspection methods are evaluated, with the aim of identifying those, which are practical for detecting defects as early in the production sequence as possible. The most promising NDT methods for P/M applications include electrical resistivity testing, eddy current and magnetic bridge testing, magnetic particle inspection, ultrasonic testing, X-ray radiography, gas permeability testing, and gamma ray density determination. The capabilities and limitations of each of the techniques are evaluated in this review. (1988)
(1.24 mb)
Material Properties
Alloy cleanliness
Microcleanlinesss Studies of Low Alloy and Carbon Steel, Powders Intended For Powder Forging Applications
i
The results of ten years of experience aimed at continuously improving the quality of powders for forging applications are reviewed. An automated image analysis procedure for inclusion assessment is described which evaluates the inclusion content of samples and defines fragmented inclusion clusters on the basis of a concept of near neighbor separation. A task group approach was used for cause-and-effect analysis to determine the source of different inclusion types and eliminate and/or reduce their incidence. The benefits of this approach are demonstrated by the significant reduction effected in inclusion levels. (1988)
(803 kb)
Materials
Alloys
Microcleanlinesss Studies of Low Alloy and Carbon Steel, Powders Intended For Powder Forging Applications
i
The results of ten years of experience aimed at continuously improving the quality of powders for forging applications are reviewed. An automated image analysis procedure for inclusion assessment is described which evaluates the inclusion content of samples and defines fragmented inclusion clusters on the basis of a concept of near neighbor separation. A task group approach was used for cause-and-effect analysis to determine the source of different inclusion types and eliminate and/or reduce their incidence. The benefits of this approach are demonstrated by the significant reduction effected in inclusion levels. (1988)
(803 kb)
Materials
Alloy Method
Fatigue Properties of PM Materials
i
The tensile properties and fatigue endurance limits of several widely used P/M steels have been tested. Statistical estimates of the 99.9% survival stress have shown that fatigue endurance ratios can vary from 0.16 to 0.47. Thus the use of 0.38 as a rule of thumb for estimating the fatigue endurance limit from static tensile property data can result in large errors. (1988)
(2.30 mb)
Process
Compaction
Fatigue Properties of PM Materials
i
The tensile properties and fatigue endurance limits of several widely used P/M steels have been tested. Statistical estimates of the 99.9% survival stress have shown that fatigue endurance ratios can vary from 0.16 to 0.47. Thus the use of 0.38 as a rule of thumb for estimating the fatigue endurance limit from static tensile property data can result in large errors. (1988)
(2.30 mb)
Material Properties
Mechanical Properties
Fatigue Properties of PM Materials
i
The tensile properties and fatigue endurance limits of several widely used P/M steels have been tested. Statistical estimates of the 99.9% survival stress have shown that fatigue endurance ratios can vary from 0.16 to 0.47. Thus the use of 0.38 as a rule of thumb for estimating the fatigue endurance limit from static tensile property data can result in large errors. (1988)
(2.30 mb)
Process
Sintering
Fatigue Properties of PM Materials
i
The tensile properties and fatigue endurance limits of several widely used P/M steels have been tested. Statistical estimates of the 99.9% survival stress have shown that fatigue endurance ratios can vary from 0.16 to 0.47. Thus the use of 0.38 as a rule of thumb for estimating the fatigue endurance limit from static tensile property data can result in large errors. (1988)
(2.30 mb)
Materials
Alloy Method
Impact and Fatigue Characterization of Selected Ferrous P/M Materials
i
Dynamic property data on pressed and sintered ferrous powder metallurgy materials have come under increasing demand as the P/M industry has grown into areas of application involving more highly stressed components. Data collected from relatively simple dynamic property tests will provide new avenues for P/M alloy development. (1987)
(922 kb)
Material Properties
Mechanical Properties
Impact and Fatigue Characterization of Selected Ferrous P/M Materials
i
Dynamic property data on pressed and sintered ferrous powder metallurgy materials have come under increasing demand as the P/M industry has grown into areas of application involving more highly stressed components. Data collected from relatively simple dynamic property tests will provide new avenues for P/M alloy development. (1987)
(922 kb)
Materials
Binder-Treatment & High Density
Properties of Parts Made From a Binder Treated 0.45 Phosphorus Containing Iron Powder Blend
i
Studies were conducted to determine the effects on property variability of parts made from a binder treated blend. The blend was a lubricated admixture of Fe3P and Ancorsteel 1000B iron powders. The parts were cylindrical bushings having a nominal wall thickness of 0.25 inches and otherwise measuring 1.5 inches in outside diameter and 2.0 inches in height. In conducting the study, an analysis of variance design was employed to enable assessment of the relative contributions of six variance sources as follows: 1) testing; 2) microsegretation; 3) part to part for pairs pressed back to back and sintered side by side; 4) sintering within trays; 5) sintering tray to tray, and 6) macrosegregation. (1987)
(164 kb)
Materials
Alloy Method
High Performance Ferrous PM Materials - The Effect of Alloying Method on Dynamic Properties
i
A comparison has been made between fully prealloyed, partially prealloyed, and elementally admixed alloys in the "as sintered" condition in order to assess the influence of microstructural and chemical homogeneity on the tensile, impact, and fatigue properties. Elementally admixed and completely prealloyed powders were prepared with chemistry similar to that of the diffusion bonded Distaloy 4600A (nominally 1.8 wt. % Ni, 1.6 wt. % Cu, and 0.55 wt. % Ho). An addition of 0.6% graphite was made to each of these materials. (1986)
(918 kb)
Material Properties
Mechanical Properties
High Performance Ferrous PM Materials - The Effect of Alloying Method on Dynamic Properties
i
A comparison has been made between fully prealloyed, partially prealloyed, and elementally admixed alloys in the "as sintered" condition in order to assess the influence of microstructural and chemical homogeneity on the tensile, impact, and fatigue properties. Elementally admixed and completely prealloyed powders were prepared with chemistry similar to that of the diffusion bonded Distaloy 4600A (nominally 1.8 wt. % Ni, 1.6 wt. % Cu, and 0.55 wt. % Ho). An addition of 0.6% graphite was made to each of these materials. (1986)
(918 kb)
Ancorbond FLM (555 kb)
