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Near Full Density As Sintered Powdered Metal (P/M) Parts

Produced From Water Atomized Powder With Properties

Comparable To Wrought Steel

Richard R. Phillips - Engineered Pressed Materials

Dennis Hammond - APEX Advanced Technologies, LLC

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Key Features of the Technology

• Water atomized powder

• Low alloy steel -100 mesh

• >99.5% theoretical density

• Properties comparable or superior to

wrought steel

• Standard tooling/ conventional pressing

• Normal compaction range

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Key Features of the Technology Continued

• High temperature sintering < 2500F (atmospheric or vacuum)

• Conventional steel heat treating

• Post heat treating operations similar to wrought processing

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Lubricant Requirements For Near Full Density P/M Parts

• Increase green density

• Mobility of the lubricant

• Effective removal of the lubricant

• Excellent dimensional stability

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High Green Density with Standard Equipment

• Reduced level of lubricant, typical use level .25%-.4%

• Green Densities 7.2-7.4 g/cc typical for common formulas

• Micro cracking and delamination eliminated• Green density increased due to reduced volume of

lubricant and better fit of particles resulting from mobility of the lubricant

• Lubricant is more effective

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Mobility of Lubricant

• Lubricant transforms with shear, pressure, and friction from a solid to a viscous liquid at relatively low pressure (~ 4 tsi with shear)

• Mobility allows for effective rearrangement of metal particles

• Mobility allows for lubricant to be forced to the die wall as well as hydrostatic environment within the compact

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Effective Removal of the Lubricant

• Environmentally friendly,contains no metal• Staggered decomposition rate• Up to 70% less gas trying to exit the part at

peak decomposition relative to conventional lubricants

• Elimination of cracking and blistering with high nickel formulas

• Elimination of recondensation of lubricant on part surfaces

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Excellent Dimensional Stability

• No micro cracks or delamination

• Small uniform pore size in the green state

• No unplanned density gradients in the part

• Relatively stress free green part

• Density split eliminated

• Uniform, predictable shrinkage

• Enhanced sintering efficiency

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Other Part Attributes

• Good surface finish

• Good ejection with reduced level of lubricant

• Due to the high green densities achieved, excellent green strength is also obtained

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Density Gradient – Shape Retention

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Density Gradient – Shape Retention

TOP

BOTTOM

B

A

C

A B C

One direction Dual Elimination of compaction direction Die Wall compaction Friction and Density Split Dg = 7.0 g/cm³ Df = 7.82 g/cm³ 7.82 7.0 ≈ 3.8 ΔL; ≈ 0.038”/in.

≈ 11.7% Increase in D

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6.20

6.60

7.00

7.40

7.80

DE

NS

ITY

(g/

cc)

Mpa 276 414 552 690 828

Green 6.38 6.79 7.04 7.19 7.29

Sintered 7.81 7.82 7.82 7.81 7.81

20 30 40 50 60

Pressure/Density Curve FLN-0706

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Materials and Processing(Experiments)

Standard MPIF ASTM Comments

Density 42 B328 Modified Method

Hardness Macro 43 E18

Impact Notched E23

Impact Un-notched 40 E23

Modulus of Elasticity 10 E8

Ultimate Tensile Strength

10 E8

Yield Strength 10 E8

Elongation 10 E8

Microstructure E3

Photomicrographs E883

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Test Alloys

•Hoeganaes Ancorsteel 85HP and 150HP formulated to provide a resulting alloy with 0.56%Carbon and Nickel contents between 2 and 6.6%.

•Pressed at 276 (20),414 (30), 552 (40) ,690 (50), and

828 (60) MPa (TSI).

•Vacuum or Atmosphere High Temperature Sintering

•Heat Treated to Commercial Wrought Steel Properties

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Tensile DataSample

TypeDensity,

g/ccUTS, MPa (103 psi)

0.2% YS, MPa (103 psi) % Elong. % ROA

Mod of Elas., GPa (106 psi)

Hardness HRC

Pressed 7.81 1,486 (215) 1,296 (187) 3.1 188 (27.3) 43.5

Machined 7.79 1,383 (200) 1,304 (189) 2.9 9.34 182 (26.4) 45.0

Pressed 7.59 1,446 (209) 1,205 (175) 4.0 158 (22.9) 39.7

Machined 7.57 1,414 (205) 1,248 (181) 4.2 10.48 162 (23.5) 38.7

Pressed 7.82 1,182 (171) 955 (138) 5.2 183 (26.6) 34.3

Machined 7.79 987 (143) 939 (136) 3.5 11.51 192 (27.8) 35.4

Pressed 7.46 1,051 (152) 685 (99) 4.4 141 (20.4) 28.0

Machined 7.57 1,314 (190) 1,211 (176) 4.9 15.92 164 (23.8) 37.5

Pressed 7.76 1,062 (154) 803 (116) 8.6 170 (24.6) 32.0

Machined 7.79 1,036 (150) 787 (114) 4.2 13.48 171 (24.8) 32.6

Pressed 7.60 1,188 (172) 690 (100) 4.0 136 (19.8) 36.7

Machined 7.57 1,089 (158) 730 (106) 7.4 15.19 135 (19.6) 32.0

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Comparison to Wrought Tensile Data

GradeUTS

MPa (103 psi)0.2% Y.S.

MPa (103 psi) % ElongationHardness, HRC Scale

ANP FLN-0706Range of Data

1,486 (215.4)1,383 (200.5)

1,296 (187.9)1,304 (189.1)

3.1/2.9 43.5/45.0

AISI 4140 1,449 (210) 1,346 (195) 14 45

AISI 4340 1,449 (210) 1,325 (192) 14 45

AISI 5140 1,304 (189) 1,228 (178) 14 40

AISI 4150 1,573 (228) 1,484 (215) 9 47

AISI 5150 1,435 (208) 1,346 (195) 11 45

AISI 6150 1,401 (203) 1,325 (192) 10 46

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Comparison to Wrought Tensile Data

GradeUTS

MPa (103 psi)0.2% Y.S.

MPa (103 psi) % ElongationHardness, HRC Scale

ANP FLN-0706Range of Data

1,182 (171.3)987 (143.1)

955 (138.4)939 (136.1)

5.2/3.5 34.3/35.4

AISI 4140 1,021 (148) 917 (133) 18 33

AISI 4340 1,049 (152) 979.8 (142) 18 34

AISI 5140 911 (132) 800 (116) 20 28

AISI 4150 1,242 (180) 1,118 (162) 12 39

AISI 5150 980 (142) 911 (132) 18 31

AISI 6150 1,125 (163) 1,063 (154) 15 36

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Comparison to Wrought Tensile Data

GradeUTS

MPa (103 psi)0.2% Y.S.

MPa (103 psi) % ElongationHardness, HRC Scale

ANP FLN-0706Range of Data

1,062 (154.0)1,036 (150.2)

803 (116.5)787 (114.2)

8.6/4.2 32.0/32.6

AISI 4140 814 (118) 697 (101) 23 22

AISI 4340 911 (132) 800 (116) 24 20

AISI 5140 787 (114) 580 (84) 27 95 HRB

AISI 4150 876 (127) 807 (117) 20 27

AISI 5150 807 (117) 711 (103) 23 23

AISI 6150 814 (118) 738 (107) 22 23

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Charpy Impact Comparison

Density, g/cc

FLN-0706

(No Notch), ft-lbf

FLN-0706

(Notched), ft-lbf

Wrought

(Notched), ft-lbf

7.8 50 7 12 - 17

7.6 55 6

7.8 77 13 36 - 56

7.6 67 11

7.8 84 77 - 87

7.6 70

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Size Change/Coefficient of Variance

Coefficient of Dimensional Variance (%)

Equal to the standard deviation divided by the average multiplied by 100

Pressed Direction 0.17%Perpendicular to Pressed Direction 0.084%

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Cylinders

Back row in the as-molded condition.Front row in sintered and heated condition.

OD = 1.880” , OAL = 1.755”, 1.500”, 0.750”, 0.500”

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Processed Samples

Samples in molded, sintered and heat treated, and machined condition. (7.81 g/cc, 45 HRC)

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Gears, Pawls and Rollers

Back row in the as-molded condition.Front row in sintered and heated condition.

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Density

6.70 g/cc(85% Theoretical Density)

7.41 g/cc(95% Theoretical Density)

7.84 g/cc(>99.5% Theoretical Density)

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Future Analysis (Fatigue)

Stress Endurance values for various sets of process conditions

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P/M and Other Process Costs

75%

100%

125%

150%

175%

200%

225%

7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9

Density (g/cm3)

Rel

ativ

e C

ost

Single Press &Sinter Warm Compaction

Double Press&

Double Sinter

High Velocity Compaction

High Velocity Compaction (Double Press – Double Sinter)

Powder Forge

ActivatedTM NanotechTM

Sinter

Machining & Precision Casting

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Conclusions• ANPTM* processing of -100 mesh ferrous powder

alloys creates material properties similar to wrought product.

• ANPTM utilizes conventional blending, tooling and P/M molding capabilities.

• Lubricant choice plays a critical role.• ANPTM is activated during high temperature sintering

resulting in densification > 99.5% of theoretical (pore-free).

• ANPTM dimensional control is predictable and uniform within < 0.2% variance.

ANPTM, ACTIVATEDTM NANOTECHTM are trademarks of Material Technologies, Inc.*Patent Pending

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Conclusions (cont.)• ANPTM can utilize conventional wrought metal

processing to meet specific engineering design requirements to enhance optimum product performance.– Machining without lubricant intrusion.– Plating without impregnation.– Salt Bath Processing

• Kolene Nu-tride• Blueing

– Ferritic Nitrocarburizing (Atmosphere).

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Conclusions (cont.)• ANPTM parts can be pressed from 276 (20) to 828

(60) MPa (TSI) and still sinter to full density.• Further development work will result in even greater

performance.• Work continuing on a broader selection of alloys.