THINK Materials and Processes

ENGINEERING THAT MOVES THE WORLD

2

The GKN Sinter Metals List of Materials provides an over-view of PM alloys that are commonly used for powder metal structural components and self-lubricating bearings includ-ing selected material properties. Other compositions can be supplied by GKN Sinter Metals when agreed with sales and technology. Modifications and supplements to the material list will be introduced without reference or notification. This does not refer to the duty of information on the current sup-ply of parts. Additional information and references are given in the brochure related to special processes or products.

Remarks Referring to the Tables

The tables are divided into four main sections Standard References I, Typical Properties (References), Chemical Compositions (Standard) and Standard References II.

Admissible ranges of density are given in the section Stan-dard References I on the left.

The range of chemical composition is listed in the section Chemical Compositions (Standard).

The section Typical Properties (References) contains in-formative values of selected material properties represent-ing a specified density value and a certain chemical compo-sition within the range specified in the section on the left and the right.

These properties should not be regarded as guaranteed properties in a legal sense.Informative property values have been determined on test bars (ISO 2740) in the as-sintered state; therefore they can-not be verified in the finished components. The use of micro tensile test bars cut out of a supplied component is not al-lowed nor can the tensile strength be deducted from a hard-ness measurement.

Many material properties are positively affected by subse-quent sizing or heat treatment. It is strongly recommended to inquire the consequences of these processes on mechan-ical and physical properties as well as on part dimensions from the supplying plant.

Determination of Properties

Mechanical and physical properties stated in the tables have been determined on the basis of Sint Test Standards (DIN 30910 Parts 1, 3 and 4).Further details are given in DIN 30910 Part 1, Section 6. The chemical composition is determined according to the respective standards.Where these are not applicable, suitable test methods should be agreed.

GKN Sinter Metals Material Lists

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Index of Contents I

Part I: Material Lists

Part II: Sintered Metal Processes

Sintered SteelsSurface Densifi ed Sintered SteelsPM Aluminium MaterialsStainless SteelsPowder Forged SteelsBearing Materials (DIN-/ISO-Standard Info)Bearing Materials (US-Standard Info)Sintered Soft Magnetical Materials Soft Magnetic Composits (SMC)MIM - Case Hardened SteelsMIM - Corrosion Resistant Steels MIM - Heat Treatable SteelsMIM - Soft Magnetic SteelsMIM - Alloys for High Temperatur Applications MIM - Tool Steels

Economical AspectsIndex of Contents IIMaterial Forming ProcessesProduction ProcessAuxiliary OperationsCompacting ToolPrinciple of PM-ToolsSurface Quality on PM PartsHardness Comparison Table Design GuidelinesTechnical SupportMarketsGKN - Innovation by Research and DevelopmentQuality - QS-ManagementNotes

4668

1012141616181818202020

222324262728293032343638404243

4

Sintered Steels

Standard References I Typical Properties (References)

GKN SM Material

Code

Density [g/cm3]

Typical composition1)Typical density [g/cm3]

UTS [MPa]

YS 0,2

[MPa]

FEL3) [MPa]

A2)

El2)

[%]

Hard-ness HB

Hard-ness HRB

E [GPa]

Remark

PMET 103P56-SP 6.5 - 6.9 Fe3Cu0.55P-0.55C 6.70 485 415 180 3 - 75 120PMET 104P56-SP 6.6 - 7.1 Fe4Cu0.55P-0.55C 7.00 590 465 215 3.5 - 85 140PMET 1000C 6.4 - 6.8 Fe 6.60 130 75 35 4 40 58 HRF 100PMET 1005C 6.4 - 6.8 Fe-0.5C 6.60 250 160 80 1.5 75 40 100PMET 1020C 6.4 - 6.8 Fe2Cu 6.60 230 185 90 2 65 25 100PMET 1000D 6.8 - 7.2 Fe 7.00 150 90 45 10 50 75 HRF 140PMET 1002D 6.8 - 7.2 Fe-0.2C 7.00 230 150 70 5 75 - 140PMET 1005D 6.8 - 7.2 Fe-0.5C 7.00 300 180 95 3 90 58 140PMET 1007D 6.8 - 7.2 Fe-0.7C 7.00 380 230 120 2 120 68 140PMET 1020D 6.8 - 7.2 Fe2Cu 7.00 270 230 75 4 85 - 140PMET 1025D 6.8 - 7.2 Fe2Cu-0.5C 7.00 500 330 160 2.5 140 70 140PMET 1025D-H1 6.8 - 7.2 Fe2Cu-0.5C 7.00 690 660 240 < 1 380 36 HRC 140 quench + temper4)

PMET 1027D 6.8 - 7.2 Fe2Cu-0.7C 7.00 560 410 180 1.5 170 74 140PMET 1205D 6.8 - 7.2 Fe2Ni0.5C 6.9 340 210 120 2 - 69 135PMET 1205D-H 6.8 - 7.2 Fe2Ni0.5C 7.1 1000 980 290 < 1 - 33 HRC 150 quench + temper4)

PMET 1208D 6.8 - 7.2 Fe2Ni0.8C 6.9 380 280 140 1 - 71 135PMET 1208D-H 6.8 - 7.2 Fe2Ni0.8C 7.0 1000 990 320 < 1 - 35 HRC 140 quench + temper4)

PMET 4602D 6.8 - 7.2 Fe1.5Cu1.75Ni0.5Mo-0.2C 7.00 470 360 150 3.5 140 60 140PMET 4602E > 7.2 Fe1.5Cu1.75Ni0.5Mo-0.2C 7.25 500 390 160 4 160 68 160PMET 4605D 6.8 - 7.2 Fe1.5Cu1.75Ni0.5Mo-0.5C 7.00 540 420 185 2.5 180 78 140PMET 4605D-H1 6.8 - 7.2 Fe1.5Cu1.75Ni0.5Mo-0.5C 7.00 1020 900 270 < 1 400 35 HRC 140 quench + temper4)

PMET 4605E > 7.2 Fe1.5Cu1.75Ni0.5Mo-0.5C 7.25 570 340 175 5 190 82 160PMET 4607D 6.8 - 7.2 Fe1.5Cu1.75Ni0.5Mo-0.7C 7.00 580 380 180 1.5 210 85 140PMET 4802D 6.8 - 7.2 Fe1.5Cu4Ni0.5Mo-0.2C 7.00 520 330 170 3.5 150 58 140PMET 4802E > 7.2 Fe1.5Cu4Ni0.5Mo-0.2C 7.25 570 350 180 4 170 66 160PMET 4805D 6.8 - 7.2 Fe1.5Cu4Ni0.5Mo-0.5C 7.00 620 340 200 2 180 84 140PMET 4805D-H1 6.8 - 7.2 Fe1.5Cu4Ni0.5Mo-0.5C 7.00 1050 820 300 < 1 380 34 HRC 140 quench + temper4)

PMET 4805E > 7.2 Fe1.5Cu4Ni0.5Mo-0.5C 7.25 700 370 200 2.5 200 89 160PMET 4807D 6.8 - 7.2 Fe1.5Cu4Ni0.5Mo-0.7C 7.00 610 380 190 1.5 230 89 140PMET 49N2D 6.8 - 7.2 Fe2Cu4Ni1.5Mo-0.2C 7.00 620 450 170 2 160 - 140PMET 49N2E > 7.2 Fe2Cu4Ni1.5Mo-0.2C 7.25 710 470 190 2.5 190 - 160PMET 49N6D 6.8 - 7.2 Fe2Cu4Ni1.5Mo-0.6C 7.00 900 650 220 1 300 - 140 sinter hardened5)

PMET 49N6E > 7.2 Fe2Cu4Ni1.5Mo-0.6C 7.25 1050 670 240 1.5 330 - 160 sinter hardened5)

PMET 49C2D 6.8 - 7.2 Fe2Cu1.5Mo-0.2C 7.00 550 400 170 1.5 150 - 140PMET 49C2E > 7.2 Fe2Cu1.5Mo-0.2C 7.25 600 450 180 2 180 - 160PMET 49C6D 6.8 - 7.2 Fe2Cu1.5Mo-0.6C 7.00 850 800 200 0.5 320 - 140 sinter hardened5)

PMET 49C6E > 7.2 Fe2Cu1.5Mo-0.6C 7.25 1000 930 220 1 400 - 160 sinter hardened5)

PMET 10P0D 6.8 - 7.2 Fe0.45P 7.00 380 230 120 10 100 - 140PMET L44N6D 6.8 - 7.2 Fe2Ni0.85Mo0.5C 7.05 550 440 220 1 - 85 145PMET L44N6D-H 6.8 - 7.2 Fe2Ni0.85Mo0.5C 7.05 1170 1000 340 < 1 - 38 HRC 145 quench + temper 4)

PMET L4206D 6.8 - 7.2 Fe0.45Ni0.6Mo0.25Mn0.5C 6.95 400 320 190 1 - 66 140PMET L4206D-H 6.8 - 7.2 Fe0.45Ni0.6Mo0.25Mn0.5C 7.0 900 890 300 < 1 - 36 HRC 140 quench + temper 4)

PMET L44NC8D 6.8 - 7.2 Fe2Ni2Cu0.85Mo0.8C 7.0 790 780 230 < 1 - 25 HRC 140 sinter hardened+ temper5)

PMET L4628D 6.8 - 7.2 Fe2Cu1.8Ni0.5Mo0.2Mn0.8C 7.0 720 710 230 < 1 - 36 HRC 140 sinter hard.+ temper5)

PMET L4618D 6.8 - 7.2 Fe1Cu2.8Ni0.5Mo0.2Mn0.8C 7.15 1000 980 290 < 1 - 36 HRC 150 sinter hard.+ temper5)

PMET 10P52 6.8 - 7.2 Fe0.55P0.2C 7.1 350 280 7) 7 - 58 150PMET 4306D 6.8 - 7.2 Fe1Cr1Ni0.85Mo0,6Si-0.6C 7.00 950 900 220 1 350 34 HRC 140 sinter hardened5)

PMET 4306D-HT 6.8 - 7.2 Fe1Cr1Ni0,85Mo0,6Si-0.6C 7.15 1150 1000 250 1 380 39 HRC 150 sinter hardened5), HT

sintered6)

1) In addition to the elements mentioned, further alloying elements up to 2 % are admitted. 2) Sizing will reduce the elongation.3) Bending load. 2 x 106 cycles, notch factor

k = 1.0 (ref. 30912 Part 6); R= -1.

4) Austenitized at 900 C, 60 minutes oil quenched; tempered at 180 - 220 C, 60 minutes, air. 5) Sinterhardening is performed in the sinter furnace by gas quenching subsequently to the sintering process. Materials can be tempered as well at 160 C 240 C for 30 min 120 min due to requirements. 6) High temperature sintering (HT) is performed at 1200 C 1300 C depending on furnace type.

5

I

Chemical Compositions (Standard)1) Standard References II

C [wt.-%]

Cu [wt.-%]

Ni [wt.-%]

Mo [wt.-%]

Cr [wt.-%]

Si [wt.-%]

P [wt.-%]

Fe [wt.-%]

Others [wt.-%]

DIN30910Sint-

ISO5755

MPIF35

0.45 - 0.65 2.0 - 4.0 - - - - 0.45 - 0.65 bal.

6

Surface Densifi ed Sintered Steels

Standard References I Typical Properties (References)

GKN SM Material

Code

Core density [g/cm3]

Surface density3) [g/cm3]

Typical composition1)

Typical core density [g/cm3]

UTS

[MPa]

YS 0,2

[MPa]

A2)

El2)

[%]

Surface hardness4)

HV0,1

Core hardness

HB

E

[GPa]

PMET 1002D/F 6.8 - 7.2 > 7.6 Fe-0,2C 7.00 230 150 5 180 75 140

PMET 1005D/F 6.8 - 7.2 > 7.6 Fe-0,5C 7.00 300 180 3 250 90 140

PMET 1025D/F 6.8 - 7.2 > 7.6 Fe2Cu-0,5C 7.00 500 330 2,5 300 140 140

PMET 1025E/F > 7.2 > 7.6 Fe2Cu-0,5C 7.25 570 360 3 300 180 160

PMET 4402D/F 6.8 - 7.2 > 7.6 Fe0,85Mo-0,2C 7.00 280 180 4 260 120 140

PMET 4402E/F > 7.2 > 7.6 Fe0,85Mo-0,2C 7.25 340 220 5 260 130 160

1) In addition to the elements mentioned, further alloying elements up to 2 % are admitted.2) Case hardening or carbo-nitriding is perfomed depending on the required case depth and is in general followed by a stress relief operation as well.3) The surface density can be exactly determined by metallographic investigations combined with quantitative image analysis.4) The indicated surface hardness is determined after the surface densification but prior to a potential heat treatment. The increased hardness at the surface can be explained by work hardening due to the deformation of the material during the densification step.

Standard References I Typical Properties (References)

GKN SM Material

Code

Density [g/cm3]

Typical composition1)Typical density [g/cm3]

UTS [MPa]

YS 0,2

[MPa]

FEL3) [MPa]

A5)

El5)

[%]

Hard-ness HB

E [GPa]

PMET Al2014 2.45 - 2.60 Al4.5Cu0.5Mg0.7Si 2.60 160 130 60 1.5 60 50

PMET Al2014-T6 2.45 - 2.60 Al4.5Cu0.5Mg0.7Si 2.60 300 280 80 1 80 57

PMET Al6061 2.50 - 2.60 Al1.0Mg0.5Si0.2Cu 2.55 160 100 - 2 40 -

PMET Al6061-T6 2.50 - 2.60 Al1.0Mg0.5Si0.2Cu 2.55 240 210 - 1 70 -

PMET Al14Si 2,55 - 2,65 Al2.5Cu0.5Mg14Si 2.62 200 150 100 1 80 79

PMET Al14Si-T6 2.55 - 2.65 Al2.5Cu0.5Mg14Si 2.62 320 300 80

7

IUTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield StrengthA, El: Fracture Elongation E: Youngs Modulus

Chemical Compositions (Standard)1) Standard References II

RemarkC

[wt.-%]

Cu

[wt.-%]

Ni

[wt.-%]

Mo

[wt.-%]

Cr

[wt.-%]

Si

[wt.-%]

P

[wt.-%]

Mn

[wt.-%]

Fe

[wt.-%]

Others

[wt.-%]

DIN30910Sint-

ISO5755

MPIF35

case hardening steel2) 0.1 - 0.5 - - - - - - - bal

8

Stainless Steels4)

Standard References I Typical Properties (References)

GKN SM Material

Code

Density [g/cm3]

Typical composition1)

Typical density [g/cm3]

UTS [MPa]

YS 0,2

[MPa]

FEL3) [MPa]

A2)

El2)

[%]

Hard-ness HB

Hard-ness HRB

E [GPa]

Remark

PMET SS303C-N1 6.4 - 6.8 Fe18Cr9Ni 6.40 270 220 90

9

I

Chemical Compositions (Standard)1) Standard References II

C [wt.-%]

Ni [wt.-%]

Mo [wt.-%]

Cr [wt.-%]

Si [wt.-%]

P [wt.-%]

Mn [wt.-%]

Fe [wt.-%]

Others [wt.-%]

DIN30910Sint-

ISO5755

MPIF35

< 0.15 8.0 - 13.0 - 17.0 - 19.0

10

Powder Forged Steels

Standard References I

Typical Properties (References)

GKN SM Material

Code

Density [g/cm3]

Typical composition1) Typical density [g/cm3]

UTS [MPa]

YS 0.2

[MPa]

FEL3) [MPa]

A2)

El2)

[%]

Hard-ness HB

E [GPa]

RemarkC

[wt.-%]Cu

[wt.-%]

PMET 1022F-H2 >7.6 Fe2Cu-0,2C 7.65 380 250 150 24 125 200 case hardening steel4) < 0.3 1.5 - 2.5

PMET 1026F >7.6 Fe2Cu-0,6C 7.65 810 530 270 12 250 200 0.4 - 0.8 1.5 - 2.5

PMET 1026FA >7.81. Fe2Cu-0.6C 7.83 950 610 4406) 8 27 HRC 210 5) 1.8 - 2.2

PMET 1036FA >7.81 Fe3Cu-0.6C 7.83 1045 745 7) 12 32 HRC 210 5) 2.8 - 3.2

PMET 4202FA >7.82 Fe0.45Ni0.6Mo0.25Mn-0.2C 7.84 520 380 7) 25 84 HRB 210 5) < 0.15

PMET 4202FA >7.82. Fe0.45Ni0.6Mo0.25Mn-0.2C 7.84 830 690 7) 23 26 HRC 210 quench + temper 5) < 0.15

PMET 4202FA >7.82 Fe0.45Ni0.6Mo0.25Mn-0.2C 7.84 1210 970 7) 9 38 HRC 210 quench + temper 5) < 0.15

PMET 4202FA >7.81 Fe0.45Ni0.6Mo0.25Mn-0.4C 7.83 900 690 7) 15 28 HRC 210 quench + temper 5) < 0.15

PMET 4202FA >7.81 Fe0.45Ni0.6Mo0.25Mn-0.4C 7.83 1320 830 7) 9 38 HRC 210 quench + temper 5) < 0.15

PMET 4202F-H2 >7.6 Fe0,45Ni0,6Mo0,25Mn-0,2C 7.65 520 380 180 20 150 200 case hardening steel4) < 0.3 -

PMET 4206F >7.6 Fe0,45Ni0,6Mo0,25Mn-0,6C 7.65 760 520 250 12 230 200 0.4 - 0.8 -

PMET 4206FA >7.8 Fe0.45Ni0.6Mo0.25Mn-0.6C 7.82 870 1170 7) 12 26 HRC 210 5) < 0.15

PMET 4206FA >7.8 Fe0.45Ni0.6Mo0.25Mn-0.6C 7.82 1250 1160 7) 8 40 HRC 210 quench + temper 5) < 0.15

PMET 4206FA >7.8 Fe0.45Ni0.6Mo0.25Mn-0.6C 7.82 1860 1650 7) 2 50 HRC 210 quench + temper 5) < 0.15

PMET 4206F-H1 >7.6 Fe0,45Ni0,6Mo0,25Mn-0,6C 7.65 1310 1170 420 5 38 HRC 200 quench + temper 0.4 - 0.8 -

PMET 4602FA >7.82 Fe1.75Ni0.55Mo0.15Mn-0.2C 7.84 550 410 7) 20 96 HRB 210 5) < 0.15

PMET 4602FA >7.82 Fe1.75Ni0.55Mo0.15Mn-0.2C 7.84 970 900 7) 24 28 HRC 210 quench + temper 5) < 0.15

PMET 4602FA >7.82 Fe1.75Ni0.55Mo0.15Mn-0.2C 7.84 1310 1070 7) 9 38 HRC 210 quench + temper 5) < 0.15

PMET 4602FA >7.81 Fe1.75Ni0.55Mo0.15Mn-0.4C 7.83 900 830 7) 15 28 HRC 210 quench + temper 5) < 0.15

PMET 4602FA >7.81 Fe1.75Ni0.55Mo0.15Mn-0.4C 7.83 1310 1070 7) 13 38 HRC 210 quench + temper 5) < 0.15

PMET 4602F-H2 >7.6 Fe1.8Ni0.55Mo-0.2C 7.65 550 410 200 20 180 200 case hardening steel4) < 0.3 -

PMET 4606FA >7.81 Fe1.75Ni0.55Mo0.15Mn-0.6C 7.83 960 660 7) 13 29 HRC 210 quench + temper 5) < 0.15

PMET 4606FA >7.81 Fe1.75Ni0.55Mo0.15Mn-0.6C 7.83 970 900 7) 13 28 HRC 210 quench + temper 5) < 0.15

PMET 4606FA >7.81 Fe1.75Ni0.55Mo0.15Mn-0.6C 7.83 1310 1070 7) 12 38 HRC 210 quench + temper 5) < 0.15

PMET 4606FA >7.81 Fe1.75Ni0.55Mo0.15Mn-0.6C 7.83 1650 1380 7) 6 48 HRC 210 quench + temper 5) < 0.15

1) In addition to the elements mentioned, further alloying elements up to 2 % are admitted.2) Sizing will reduce the elongation.3) Bending load. 2 x 106 cycles, notch factor k = 1.0 (ref. 30912 Part 6); R = -1.4) Case hardening or carbo-nitriding is perfomed depending on the required case depth and is in general followed by a stress relief operation as well.5) Carbon content shall be as specified by the purchaser. Unless agreed upon between the purchaser and manufacturer, the forged product carbon content shall be within +/- 0.1% of the specified carbon content.6) For FEL, polished specimen and R = 0.1. Runout 1 x 107 cycles. Other fatigue information available on request.7) Details on request.

11

I

UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield StrengthA, El: Fracture Elongation E: Youngs Modulus

Chemical Compositions (Standard)1) Standard References II

Ni [wt.-%]

Mo [wt.-%]

Cr [wt.-%]

Si [wt.-%]

P [wt.-%]

Mn [wt.-%]

Fe [wt.-%]

Others [wt.-%]

DIN30910Sint-

ISO5755

MPIF35

ASTMB 848

- - - - - - bal.

12

Bearing Materials (DIN-/ISO-Standard Info)

1) In addition to the elements mentioned, further alloying elements up to 2 % are admitted.2) The oil content is at least 90 % of the open porosity.3) Values determined after sizing.4) Carbon mainly in the form of free graphite.

Standard References I Typical Properties (References)

GKN SM Material Code

Density [g/cm3]

Typical composition1)

Typical density [g/cm3]

Porosity2) [%]

K-Factor3) [N/mm2]

Hardness HB

RemarkC

[wt.-%]

PMET B-ILD 5.6 - 6.0 Fe 5.8 26 170 30 Fe-base -

PMET B-IMD 6.0 - 6.4 Fe 6.2 21 220 40 Fe-base -

PMET B-T1LD 5.6 - 6.0 Fe2Cu 5.8 26 200 40 Fe-base -

PMET B-T1MD 6.0 - 6.4 Fe2Cu 6.2 21 250 50 Fe-base -

PMET B-FLD4) 5.6 - 6.0 Fe36Cu4Sn1C 5.8 27 90 40 Fe-base 0.8 - 1.2

PMET B-FMD4) 6.0 - 6.4 Fe36Cu4Sn1C 6.2 22 120 50 Fe-base 0.8 - 1.2

PMET B-M211LD4) 5.4 - 5.8 Fe1,5Cu3C 5.6 24 70 45 Fe-base 2.5 - 3.5

PMET B-M211MD4) 5.8 - 6.2 Fe1,5Cu3C 6.0 18 80 55 Fe-base 2.5 - 3.5

PMET B-M36MD4) 6.0 - 6.4 Fe3Cu1,5C 6.2 18 170 60 Fe-base 1.0 - 2.0

PMET B-M21MD4) 6.0 - 6.4 Fe2Cu0,4C 6.2 20 270 70 Fe-base 0.2 - 0.6

PMET B-MP208LD4) 5.6 - 6.0 Fe20Cu1,8C 5.8 25 120 40 Fe-base 1.2 - 2.4

PMET B-MP208MD4) 6.0 - 6.4 Fe20Cu1,8C 6.2 20 140 50 Fe-base 1.2 - 2.4

PMET B-QLD 6.4 - 6.8 Cu9Sn 6.6 25 140 30 Bronze -

PMET B-QMD 6.8 - 7.2 Cu9Sn 7.0 20 180 35 Bronze -

PMET B-H4LD4) 6.2 - 6.6 Cu9Sn1,5C 6.4 24 120 30 Bronze 1.0 - 2.0

PMET B-H4MD4) 6.6 - 7.0 Cu9Sn1,5C 6.8 19 160 35 Bronze 1.0 - 2.0

13

I

See special GKN catalogue for bearing materials

Chemical Compositions (Standard)1) Standard References II

Cu [wt.-%]

Sn [wt.-%]

Fe [wt.-%]

Others [wt.-%]

DIN30910 Sint-

ISO5755

MPIF35

- - bal.

14

Bearing Materials (US-Standard Info)

Standard References I Typical Properties (References)

GKN SM Material

Code

Wet Density [g/cm3]

Typical Composition1)

Typical Wet Density

[g/cm3]

MIn. K-Factor [N/mm2]

MinimumOil Content

[%]Remark

PMET B-B0000 6.0 - 6.4 Cu10Sn 6.2 130 24 Low graphite bronze

PMET B-B0000-A 6.4 - 6.8 Cu10Sn 6.6 180 19 Low graphite bronze

PMET B-B0000-B 6.8 - 7.2 Cu10Sn 7.0 260 12 Low graphite bronze

PMET B-B00012 6.0 - 6.4 Cu10Sn1C 6.2 120 22 Medium graphite bronze

PMET B-B00012-A 6.4 - 6.8 Cu10Sn1C 6.6 160 17 Medium graphite bronze

PMET B-B00012-A 6.8 - 7.2 Cu10Sn1C 7.0 210 17 Medium graphite bronze

PMET B-B00025-A 5.8 - 6.2 Cu10Sn3C 6.0 70 11 High graphite bronze

PMET B-B00025-B 6.2 - 6.6 Cu10Sn3C 6.4 100 5 High graphite bronze

PMET B-DB10365-A 5.6 - 6.0 Fe36Cu4Sn1C 5.8 110 22 Diluted bronze

PMET B-DB10365-B 6.0 - 6.4 Fe36Cu4Sn1C 6.2 150 17 Diluted bronze

PMET B-DB005410-A 5.6 - 6.0 Cu38Fe6Sn1C 5.8 100 22 Diluted bronze

PMET B-DB005410-B 6.0 - 6.4 Cu38Fe6Sn1C 6.2 150 17 Diluted bronze

PMET B-1000-A 5.6 - 6.0 Fe 5.8 100 21 Iron

PMET B-1000-B 6.0 - 6.4 Fe 6.2 160 17 Iron

PMET B-1005-A 5.6 - 6.0 Fe0.5C 5.8 140 21 Iron-Carbon

PMET B-1005-B 6.0 - 6.4 Fe0.5C 6.2 190 17 Iron-Carbon

PMET B-1008-A 5.6 - 6.0 Fe0.8C 5.8 140 21 Iron-Carbon

PMET B-1008-B 6.0 - 6.4 Fe0.8C 6.2 220 17 Iron-Carbon

PMET B-1020-A 5.6 - 6.0 Fe2Cu 5.8 140 22 Iron-Copper

PMET B-1020-A 6.0 - 6.4 Fe2Cu 6.2 230 17 Iron-Copper

PMET B-10100-A 5.6 - 6.0 Fe10Cu 5.8 140 22 Iron-Copper

PMET B-10100-B 6.0 - 6.4 Fe10Cu 6.2 210 19 Iron-Copper

PMET B-1025-A 5.6 - 6.0 Fe2Cu0.5C 5.8 140 22 Iron-Copper-Carbon

PMET B-1025-B 6.0 - 6.4 Fe2Cu0.5C 6.2 240 17 Iron-Copper-Carbon

PMET B-1028-A 5.6 - 6.0 Fe2Cu0.8C 5.8 170 22 Iron-Copper-Carbon

PMET B-1028-B 6.0 - 6.4 Fe2Cu0.8C 6.2 280 17 Iron-Copper-Carbon

PMET B-1058-A 5.6 - 6.0 Fe5Cu0.8C 5.8 240 22 Iron-Copper-Carbon

PMET B-1058-B 6.0 - 6.4 Fe5Cu0.8C 6.2 320 17 Iron-Copper-Carbon

PMET B-10208-A 5.6 - 6.0 Fe20Cu0.8C 5.8 300 22 Iron-Copper-Carbon

PMET B-10208-B 6.0 - 6.4 Fe20Cu0.8C 6.2 320 17 Iron-Copper-Carbon

PMET B-10023G-A 5.6 - 6.0 Fe0.3C2.5Gr 5.8 170 18 Iron-Graphite

PMET B-10023G-B 6.0 - 6.4 Fe0.3C2.5Gr 6.2 240 12 Iron-Graphite

1) In addition to the elements mentioned, further alloying elements up to 2 % are admitted.

I

15

Chemical Compositions (Standard)1) Standard References II

C [wt.-%]

Cu [wt.-%]

Sn [wt.-%]

Fe [wt.-%]

Graphite [wt.-%]

Others [wt.-%]

DIN 30910Sint- ISO-5755 MPIF

0.0 - 0.3 87.2 - 90.5 9.5 - 10.5 - -

16

Standard References I Typical Properties 1)

GKN SM Material

Code

TypicalDensity [g/cm]

Coercivity Hc

[A/m]

Bmax@ 1200

A/m [T]

Perme-ability

Hard-ness

Hard-ness

UTS [MPa]

YS0,2

[MPa]

AEl

[%]

E [GPa]

Compo-sition

PM4EM 1000D 7.0 145 1.05 2,300 50 HRF 50 HB 195 115 12 140 Fe

PM4EM 1000E 7.25 145 1.20 2,900 55 HRF 55 HB 255 155 17 155 Fe

PM4EM 10P40D 7.15 120 1.25 3,200 55 HRB 95 HB 380 270 12 155 Fe0.45P

PM4EM 10P40E 7.4 120 1.35 3,600 65 HRB 115 HB 415 280 15 170 Fe0.45P

PM4EM 10S30D 7.2 80 1.30 5,000 75 HRB 135 HB 380 275 15 155 Fe3Si

PM4EM 50NiE 7.5 25 1.20 10,000 40 HRB 80 HB 275 170 15 110 Fe50Ni

PM4EM SS410C 6.7 390 1.15 340 85 HRB 165 HB 280 150 10 125 Fe12Cr

PM4EM SS410D 7.0 330 1.23 410 95 HRB 210 HB 320 190 14 140 Fe12Cr

PM4EM SS430C 6.7 320 1.06 320 70 HRB 120 HB 300 170 12 125 Fe16Cr

PM4EM SS430D 7.0 280 1.17 370 90 HRB 185 HB 340 200 16 140 Fe16Cr

Sintered Soft Magnetic Materials

1) Properties can be influenced and optimized by the proper selection of processing conditions. Consult an GKN Sinter Metals expert on the specifics of the application for the best solution.2) C

17

I

Chemical Composition2) Standard References II

ApplicationsFe

[wt-%]P

[wt-%]Ni

[wt-%]Si

[wt-%]Cr

[wt-%]Other [wt-%]

DIN EN 10331

DIN 30910Sint-

MPIF

bal. - - - - < 0.5 S-Fe-165 D 00 FF-0000-20W

applications at DC & low frequency cur-rent or permant magnetic systems

bal. - - - - < 0.5 S-Fe-150 E 00 FF-0000-20X

bal. 0.45 - - - < 0.5 S-FeP-130 D 35 FY-4500-17X

bal. 0.45 - - - < 0.5 S-FeP-110 E 35 FY-4500-17Y

bal. - - 3 - < 0.5 S-FeSi-80 n/a FS-0300-12X

bal. - 50 - - < 0.5 S-FeNi-20 n/a FN-5000-5Z

bal. - - - 13 < 1 n/a C 43 SS-410L

applications at DC & low frequency cur-rent or permant magnetic systems with high corrosion resistance

bal. - - - 13 < 1 n/a D 43 SS-410L

bal. - - - 18 < 1 n/a C 42 SS-430L

bal. - - - 18 < 1 n/a D 42 SS-430L

UTS: Ultimate Tensile Strength YS: Yield Strength A, El: ElongationE: Youngs Modulus

ApplicationsTransverse

RuptureStrength

TRS [MPa]

Density [g/cm]P @ 2000Hz

[W/kg]

384 39 up to 7.4

BLDC electric motors; transverse and axial fl ux machines; transformers; high frequency softmagnetic application

617 121 up to 7.4

377 42 up to 7.5

426 136 up to 7.5

385 48 up to 7.3

501 100 up to 7.3

329 62 up to 7.3

498 149 up to 7.3

18

MIM - Case Hardened Steels

MIM - Heat Treatable Steels

Material

Sintered Heat Treated Chemical Compositions1)

Density[g/cm]

Rm

[MPa]R

p 0.2

[MPa]A

[%]Hardn.[HV 10]

Rm

[MPa]R

p 0.2

[MPa]

AEl

[%]

Hardn.[HV 10]

C[%]

Ni[%]

Cr[%]

Mo[%]

Mn[%]

IMET Ni 2 > 7,40 280 140 25 90 by agreement < 0.1 1.90-2.20 - - -

IMET Ni 8 > 7,40 350 200 15 90 by agreement < 0.1 7.50-8.50 - - -

IMET 8620 > 7,40 400 220 15 90 by agreement 0.12-0.230.40-0.70

0.40-0.60

0.15-0.25 -

Material

Sintered Heat Treated Chemical Composition1)

Density[g/cm]

Rm

[MPa]R

p 0.2

[MPa]A

[%]

Hard-ness

[HV 10]

Rm

[MPa]R

p 0.2

[MPa]

AEL[%]

Hardness[HV 10]

C[%]

Ni[%]

Cr[%]

Mo[%]

Mn[%]

Si[%]

IMET Ni 2C > 7.40 450 250 5 170 1000 800 2 600 0.40-0.701.90-2.20 - - - -

IMET Ni 8C > 7.40 700 350 3 320 1200 1000 2 600 0.40-0.707.50-8.50 - - - -

IMET Cr Mo 4 > 7.40 600 350 4 110 1350 1150 2 450 0.35-0.45 -0.90-1.20

0.15-0.30 - -

IMET 8740 > 7.40 600 350 5 180 1600 1100 1 450 0.45-0.550.50-0.80

0.40-0.60

0.25-0.40 -

0.30-0.55

IMET Cr 6 > 7.40 950 630 5 250 1500140012501100

10.5

450650

0.80-1.05 -

1.35-1.65 - - -

Material

Sintered Heat Treated Chemical Composition1)

Density[g/cm]

Rm

[MPa]R

p 0.2

[MPa]A

[%]Hardn.[HV 10]

Rm

[MPa]R

p 0.2

[MPa]

AEL[%]

Hardn.[HV 10]

C[%]

Ni[%]

Cr[%]

Mo[%]

Mn[%]

Si[%]

IMET 316 L > 7.60 450 160 40 105 n/a

19

I

Other Designation

Properties Applications Si

[%]Cu[%]

Fe[%]

Mat no: DIN

AISI/SAE/MPIF

Others

- - bal. n/a MPIF MIM - 2200carbonyl iron with 2% nickel high strength, fatigue strength, high

surface hardnessmechanical engineering

- - bal. n/a MPIF MIM - 2700carbonyl iron with 8% nickel

- - bal. 1.6523 AISI/SAE 8620 21 NiCrMo 2for parts with the highest mechanical loading, high surface hardness

gear segments, crown wheels, cam-shafts, tools, mechanical engineering

Other Designation

Properties ApplicationsFe[%]

Mat no: DIN

AISI/SAE Others

bal. n/a n/a carbonyl iron with 2% nickel

excellent surface fi nish, high strength miscellaneous applications (e. g. mechanical engi-neering, fi rearm components)

bal. n/a n/a carbonyl iron with 8% nickel

bal. 1.7225 AISI/SAE 4140 42 CrMo 4 high strength and ductility, large heat treated diameter

mechanical engineering, fi rearms, gearbox com-ponents

bal. 1.6546 AISI/SAE 8740 40NiCrMo2 2wear resistant, highly loaded components in me-chanical engineering and automotive industry

bal. 1.3505 AISI/SAE 52100 100 Cr 6cold working tool steel, high wear resis-tance, high hardness

mechanical engineering

Other Designation

Properties ApplicationsCu[%]

Nb[%]

Fe[%]

Mat no:DIN

AISI/SAE Others

- - bal. 1.4404 AISI 316 LX 2 Cr-NiMo 17 13 2

excellent corrosion resistance, austenitic, non-magnetic, moderate hardness, high ductility, excellent polished surface and shape reproduction

apparatus engineering, chemical industry, watchmaking and jewellery, medical technology

- - bal. 1.4016 AISI 430 X 6 Cr 17 high strength and corrosion resistance, ferritic

automotive industry

3.00- 5.00

0.15-0.45 bal. 1.4542

SAE J 467 (17-4PH)

X 5 CrNi-CuNb 17 4

high corrosion resistance, martensitic, ferro-magnetic, precipitation hardening

pump components, medical enginee-ring, automotive industry, mechanical engineering, aircraft and shipbuilding industries

Rm

: ultimate tensile strength RP0.2

: yield strength A, El: elongation to fracture

20

MIM - Soft Magnetic Steels

Material

Sintered Heat Treated Chemical Comp

Density[g/cm]

Rm

[MPa]R

p 0.2

[MPa]A

[%]

Hard-ness

[HV 10]

Rm

[MPa]R

p 0.2

[MPa]

AEl

[%]

Hardn.[HV 10]

C[%]

Ni[%]

Cr[%]

Mo[%]

Mn[%]

IMET Si 3 > 7.40 450 300 20 160 n/a < 0.1 - - - -

IMET FN 50 > 7.40 400 150 25 110 n/a < 0.1 49.50-50.50 - - -

IMET F S > 7.40 220 100 40 60 n/a < 0.1 - - - -

Material

Sintered Heat Treated Chemical Com

Density[g/cm]

Rm

[MPa]R

p 0.2

[MPa]A

[%]Hardn.[HV 10]

Rm

[MPa]R

p 0.2

[MPa]

AEl

[%]

Hardn.[HV 10]

C[%]

Ni[%]

Cr[%]

Mo[%]

Co[%]

Al[%]

IMET GHS-4 *) >7.70 700 550 1 310 n/a 2.0-2.4 38.0-42.0 11.0-13.0 5.0-7.0 - -

IMET 310N **) >7.55 650 380 7 220 n/a 0.20-0.50 19.0-22.0 24.0-26.0 - - -

IMET N 90 ***) > 7.8 1000 620 10 280 1100 650 10 300 0.13 bal. 18.0-21.0 - 15.0-21.0 1.0-2.0

MIM - Alloys for High Temperature Applications

MIM - Tool Steels

Material

Sintered Heat Treated Chemical

Density[g/cm]

Rm

[MPa] R

p 0.2

[MPa]A

[%]Hardn.[HV 10]

Rm

[MPa]R

p 0.2

[MPa]

AEl

[%]

Hardness[HV 10]

C[%]

Cr[%]

W[%]

IMET M2 > 7.70 1100 700 1 480 - - - 800 0.95-1.05 3.80-4.50 5.50-6.75

1) Percent by weight

*) Heat and wear resistant alloy **) Heat resistant alloy ***) Superalloy

21

I

position1) Other Designation

Properties ApplicationsSi

[%]Cu[%]

Fe[%]

Mat no: DIN

AISI/SAE/MPIF Others

2.50-3.00 - bal. 1.0884 MPIFMIM-Fe-3%Sicarbonyl iron w. 3% silicium relatively high

permeability

for pole shoes and relay components (where fast magnetic reversal is required)

- - bal. 1.3926 MPIFMIM-Fe-50%Nicarbonyl iron w. 50% nickel pole shoes, relay parts, rotors, stators, etc.

- - bal. n/a n/a carbonyl iron high polarisation

mposition1) Other Designation

Properties ApplicationsTi

[%]Si

[%]Mn[%]

V[%]

Nb[%]

Fe[%]

Mat no:DIN

AISI/SAE Others

- 1.5-1.9 0.8-1.3 0.8-1.0 - bal. n/a n/a PI Ni 40 Cr 12 Mo 6 high application tempe-rature, wear resistant

turbocharger

- 0.75-1.30

22

TM

The PM production technique excels when compared with the cost of other different metal shaping processes. Three important criteria characterize the process:

In spite of the fact that metal powder is more expensive than conventional steel, this difference is offset by the ad-vantage of nearly 100 % material utilization. This holds for the typical PM part of less than 1 kg in weight and also for heavier parts, whereas the initial weight of the conventional steel blank is much greater than that of the machined part.

The large amount of design capability leads to parts that may combine several functions in one component, often replacing multiple piece assemblies made by blanking or machining. For example, inner and outer gears, through and blind holes of varied profi les, and countersunk or stepped openings may be produced in a single shaping operation.

The effi ciency depends on the operating speed of the press, the fl ow properties of the powder and the height of the com-ponents to be compacted. The sintering costs are infl uenced by the required material quality, sintering temperature and time, protective atmosphere, but are fairly independent from parts geometry.

The parameters of the manufacturing process are deter-mined by the functional requirements of the component properties, related to the chemical composition, density and precision of the component. Cost comparison with competing technologies, such as stamping, cold extrusion, precision casting, precision forging and plastic moulding is strongly infl uenced by requirements of material, shape and production quantity.

The higher the requirements on material properties, the closer the tolerances required, and larger the production quantity the greater the advantage is for using a sintered component. Even when machining is necessary due to close tolerances or to geometry, the overall economics of a sin-tered blank often turn out to be favourable.

Although the PM shaping process is fl exible as to quanti-ties, initial investment in tooling requires larger production runs.

A further signifi cant advantage - the PM process saves nat-ural resources through recycling, conserves raw materials and the manufacturing process yields low emissions.

Economical and Ecological Aspects

100 % material utilization (no scrap loss) wide variety of designs possible with limited impact on production costs, and according to customer application needs wide range of adaptability of material properties to the function of the componentsenvironmental friendly

23

Index of Contents II

Part I: Material Lists

Part II: Sintered Metal Processes

Sintered SteelsSurface Densifi ed Sintered SteelsPM Aluminium MaterialsStainless SteelsPowder Forged SteelsBearing Materials (DIN-/ISO-Standard Info)Bearing Materials (US-Standard Info)Sintered Soft Magnetical Materials Soft Magnetic Composits (SMC)MIM - Case Hardened SteelsMIM - Corrosion Resistant Steels MIM - Heat Treatable SteelsMIM - Soft Magnetic SteelsMIM - Alloys for High Temperatur Applications MIM - Tool Steels

Economical AspectsIndex of Contents IIMaterial Forming ProcessesProduction ProcessAuxiliary OperationsCompacting ToolPrinciple of PM-ToolsSurface Quality on PM PartsHardness Comparison Table Design GuidelinesTechnical SupportMarketsGKN - Innovation by Research and DevelopmentQuality - QS-ManagementNotes

4668

1012141616181818202020

222324262728293032343638404243

24

General Remarks

The sinter metal process covers a wide range of manufactured parts; from highly porous materials for fi lter applications, to full or near full dense components such as sinter forged engine and gear box parts.

Material Forming Processes

Conventional PM

The majority of PM products are manufactured using the Conventional method pio-neered in the 1930s. Improvements in materials and processes has resulted in a new class of high performance, consistent, competitive and creative product.

Aluminium PM

New PM Aluminium materials developed by GKN are challenging paradigms about material performance offering a new option to engineers when weight reduction and performance improvement are priorities.

Porous Metal Filters

Filters and associated components based on GKNs controlled porosity materials are depended on in a wide variety of demanding applications where traditional fi lters are unable to deliver the required performance.

Powder Forging

This process step creates a nearly full dense part with high dynamic loads by utilizing a closed die which creates high axial precision.

25

II

Surface Densifi ed PM

A new PM technology that enables high density performance where required, without the weight penalty of fully dense products. This is an ideal process for complex, highly stressed gears requiring high performance and light weight.

Metal Injection Moulding

Delivering the three dimensional shape capability of plastic injection moulding com-bined with the performance of alloy steels, stainless steels and high temperature al-loys, MIM is uniquely positioned to solve extreme product challenges.

Sintered Bearings

Sintered self-lubricating bearings are indispensible machine elements. When used in typical applications, they are much more cost effective than roller bearings and even require less space. In contrast to plastic bearings, sintered bearings exhibit a pore vol-ume of 15 to 30 percent which serves as an oil reservoir for the entire lifetime.

Soft Magnetic PM

Growing demand for electric motors and electro-mechanical systems has highlighted a need for new design and material solutions. PM technology and new soft magnetic materials enable engineers to develop smaller products with improved performance.

26

1. Blending / Mixing

Raw material in powder form is mixed according to the specified composition. Prealloyed powders may be used as well as elemental powders.

2. Compaction

Compaction of components is carried out in specially designed tools. By selecting the compaction pressure usually in the range of 400 - 800 MN/m2, the density can be varied within wide lim-its.

3. Sintering

During sintering (heating under controlled conditions of time, temperature and protective atmosphere) the compacted parts obtain their mechanical strength. Sintering, which takes place below the melting temperature of the major constituent of the material, results in interparticle bonding without appreciably changing the shape of the component. During sintering diffusion and recrystallization occur.

4. Sizing / Forging

Sizing: Sintering may produce small dimensional changes in the compacts. Therefore, parts with very close tolerances, are sized in separate tools. The sized component has an excellent surface finish. Forging: To produce parts for extremely high duty applications a forging operation is carried out at high temperature instead of sizing at room temperature and with the advantage of no need for burr removal.

5. Finished Part

In most of the cases the production process ends latest after siz-ing / forging, leaving behind the finished part. However, if the customer requires closer tolerances or more complex shapes, GKN is able to fulfill these with auxiliary operations.

Production Process

Lubricant Graphite

CopperPowder

Alloying Elements IronPowder Powder Blends

Lubricantburn-off

Sintering Cooling

Sizing Forging

27

II

Production Process - Optional Auxiliary Operations

Optional Auxiliary Operations - Examples

Joining Machining Heat treatment Surface treatment

Turned inner cone

Surface densification by rolling process

Induction hardened teeth

Turned outer diameter

Ground surface

Organic coated surface

28

Part complexity requires sophisticated compacting tool de-sign, the use of core rods for holes, split punches and ad-justable powder fills for multilevel parts. For achieving uni-form density in the part, the respective motions of die and lower punches are calculated and programmed in the press operating cycle.

Even undercuts can be produced with a special technology being invented by GKN Sinter Metals.

In most cases, tooling is made from high speed steel or car-bide, and the life time may range from 10,000 to millions of parts, depending on complexity, materials and tolerances.

The Compacting Tool

For the production of the PM components, the metal pow-der must be compressed so that the individual particles will cold-weld at their contact points to make a part of sufficient green strength to be handled and of a density great enough to meet specified properties. The design and quality of the compacting tool must be such that the part will be, after sin-tering, of the desired strength and dimensions.

In the most simple case for a tablet shape the tool con-sists of a die, and an upper and lower punch. Individually controlled press movement of these tool components con-trols the powder fill, compression stroke, and part ejection.

Upper punch

Die

Die plate

Lower punch

Core rod

Base plate

Joining plate

29

II

Principle of PM-Tools - Dimensional Accuracy

The process of axial compaction offers a wide variety of shaping possibilities and leads to excellent reproducibility of the dimensions. The shaping of a sintered component is essentially defined by the tool design and its manufacture.The appropriate lay-out of the components geometry and selection of the suitable material according to the PM pro-cess has a strong influence on tool life and -consequently- on the price of the part. It is therefore worthwhile to consider some of the guidelines of design related to the PM process. The specific forming parts of a tool are a die, core rod, upper and lower punch. The most important options in the design of a compacting tool are demonstrated in figure 1.The die creates the outer shape of the component. It may have any geometry. Steps or slopes are possible in the axial direction. Bores and apertures in the direction of compact-ing are shaped by core rods, which also may be contoured. The face contours of the parts are shaped by punches. Sharp chamfers or sharp junctions to the area of the outer surface have to be avoided. Steps of max. 15 % of the final compo-nent height can be produced without split punches.

To avoid tooling problems a minimum wall thickness of 2 mm should be maintained. The following aspects are im-portant for the ejection of the part from the die:

Ejection draft angles on profile of the outer surface are not necessaryFace contours should have draft angles of less than 7Junctions and edges should have radii when formed in the die

Possibilities to press threads, grooves and bores perpendic-ular to the compacting direction are very limited and most often need to be added as secondary machining. However due to a special GKN owned technology undercuts are very possible to a certain extent. The design guidelines are shown on page 34.

Dimensional Accuracy

GKN Sinter Metals endeavours during the development phase to find a custom tailored solution for production runs and offers components fulfilling exactly the requirements of dimensional accuracy and performance.The design and manufacturing of the tools directly influence the tolerances of the components. Tolerances of shape and position are mainly influenced by the tool assembly. They are governed by the clearances between punches and die or punches and core rods respectively. For parts with several split punches (multi level parts) the clearances add up to re-duce the total accuracy. Tolerances in height are influenced by the stiffness of the compacting or sizing presses and are typically between 0.1 and 0.2 mm. Closer tolerances as de-scribed above (Figure 2) can be attained by additional ma-chining operations. The small distortion caused by sintering process can be corrected by sizing (cold repressing) of the parts. Depending on density and material of a part an im-provement of the dimensional quality can be achieved from e.g. ISO/IT 8-9 to ISO/IT 6-7. An additional advantage of the sizing step is the increase in density and improvement of the surface quality. Additional influences on the dimen-sional accuracy of a component are caused by subsequent surface or heat treatment operations.

Tolerance classes of unmachined, sized components

Figure 1

Figure 2

Tool for a component with 1 cross section

Tool with stepped die

Tool with stepped conical die

Tool for a component with multi cross

section

Tool with double top punch for a component with multiple cross

section

Tool with split die

30

''

''

Today surface qualities on sintered parts are often still de-fined by Rt, Ra or Rz using values that seem to be based on experiences with machined surface qualities on non porous materials.

Due to the special (porous) structure of PM components the surface measurement with current measuring devices ac-cording to DIN EN ISO 4287 und 4288 is misleading and does not reflect the high quality of sintered surfaces. Hence deep pores may create extremely high Rt values even though the surface is plateau like and thus contains extraordinary well gliding properties.

By comparing profiles of surfaces from machined parts with porous PM components it becomes obvious that PM mate-rials offer without doubt an improved surface smoothness although the Pt values from the compared St 50 vs. PM mea-surement plots are almost identical.

Due to the special surface properties of sintered parts it is therefore recommended to define roughness in Rpk and Rk (see ISO 23519). The adjoining pictures and table 1 serve to illustrate this.

Surface Quality on PM Parts (ISO 23519)

a) St 50 fine turned (Pt ~ 30)

c) Sint-C 00 as sintered (Pt ~ 30)

Figures a - d) Surface profiles of materials according to table 1

Table 1 Surface roughness measured on different processing conditionsof steel and PM parts (examples)

Figure Processing ConditionRough

Rt Ra

a) St 50 fine turned 10.7 1.28b) St 50 grinded 4.2 0.6c) SINT-C 00 as sintered 28 1.9d) SINT-C 00 sized 10.6 1.22

Today surface qualities on sintered parts are often still de-fined by Rt, Ra or Rz using values that seem to be based on experiences with machined surface qualities on non porous materials.

Due to the special (porous) structure of PM components the surface measurement with current measuring devices ac-cording to DIN EN ISO 4287 und 4288 is misleading and does not reflect the high quality of sintered surfaces. Hence deep pores may create extremely high Rt values even though the surface is plateau like and thus contains extraordinary well gliding properties.

By comparing profiles of surfaces from machined parts with porous PM components it becomes obvious that PM mate-rials offer without doubt an improved surface smoothness although the Pt values from the compared St 50 vs. PM mea-surement plots are almost identical.

Due to the special surface properties of sintered parts it is therefore recommended to define roughness in Rpk and Rk (see ISO 23519). The adjoining pictures and table 1 serve to illustrate this.

Surface Quality on PM Parts (ISO 23519)

a) St 50 fine turned (Pt ~ 30)

c) Sint-C 00 as sintered (Pt ~ 30)

Figures a - d) Surface profiles of materials according to table 1

Table 1 Surface roughness measured on different processing conditionsof steel and PM parts (examples)

31

II

''

''

b) St 50 grinded (Pt ~ 6)

d) Sint-C 00 sized (Pt ~ 6)

ness Values in mContact Area in % at Cutting Depth c

Rz Rpk Rk 1 m 2 m 4 m

8.2 4.5 5.4 < 1 6 123.6 1.3 1.4 < 1 71 10018 1.4 1.4 < 1 56 727.8 0.8 0.6 96 98 100

b) St 50 grinded (Pt ~ 6)

d) Sint-C 00 sized (Pt ~ 6)

32

TensileStrength

Rm

Vickers Hardness

HV (F>98 N)

BrinellHardness

HB

Rockwell Hardness

HRC HRA HRB HRF

255 80 76,1

285 90 85,6 48,0 82,6

320 100 95,1 56,2 87,0

350 110 104,6 62,3 90,5

385 120 114,1 66,7 93,6

415 130 123,6 71,2 96,4

450 140 133,1 75,0 99,0

480 150 142,6 78,7 101,4

510 160 152,1 81,7 103,6

545 170 161,6 85,0 105,5

575 180 171,1 87,1 107,0

610 190 180,6 89,5 108,7

640 200 190,1 91,5 110,1

675 210 199,7 93,5 111,3

705 220 209,2 95,0 112,4

740 230 218,7 96,7 113,4

770 240 228,2 20,3 60,7 98,1 114,3

800 250 237,7 22,2 61,6 99,5 115,1

835 260 247,2 24,0 62,4 101

865 270 256,7 25,6 63,1 102

900 280 266,2 27,1 63,8 104

930 290 275,7 28,5 64,5 105

965 300 285,2 29,8 65,2

1030 320 304,2 32,2 66,4

1095 340 323,3 34,4 67,6

Hardness Comparison Table

33

II

TensileStrength

Rm

Vickers Hardness

HV (F>98 N)

BrinellHardness

HB

Rockwell Hardness

HRC HRA HRB HRF

1155 360 342,3 36,6 68,7

1220 380 361,3 38,8 69,8

1290 400 380,3 40,8 70,8

1350 420 399,3 42,7 71,8

1420 440 418,3 44,5 72,8

1485 460 437,3 46,1 73,6

1555 480 456,4 47,7 74,5

1595 490 465,9 48,4 74,9

1665 510 484,9 49,8 75,7

1740 530 503,9 51,1 76,4

1810 550 522,9 52,3 77,0

1880 570 541,9 53,6 77,8

1955 590 560,9 54,7 78,4

2030 610 580,0 55,7 78,9

2105 630 599,0 56,8 79,5

2180 650 618,0 57,8 80,0

2251 670 637,0 58,8 80,6

2325 690 656,0 59,7 81,1

2399 720 684,5 61,0 81,8

2472 760 722,6 62,5 82,6

2546 800 760,6 64,0 83,4

2619 840 798,6 65,3 84,1

2693 880 836,7 66,4 84,7

2766 920 874,7 67,5 85,3

2840 940 893,7 68,0 85,6

34

Design Guidelines I

Gear pitch dia. up to max. 2. 2 up to pitch dia. or more, inner or outer chamfers see detail Z; Posi-tioning/identification Mark M on upper face embossed < 0.2 or optionally engraved.

Undercuts, threads, cross bores not feasi-ble by compaction (secondary operation). Position marks, chamfers or curvatures only in direction outer diameter, otherwise edges too sharp.

Apertures and edges require radii 0.3. Bores straight through, for blind holes di-ameter to depth ratio max. 1:2. Except worm gear, all other gear shapes feasible; helical gear only up to 30 max.

Round aperturespreferred.

Wall thicknessS = 2 mm min.

Version A or B preferredto avoid tangential junction

Burr 0.15 permissible(burr pockets)

Replace sharp edges by plain diameter

avoid

Tangential junction

A 2 mm B 2 mmC 2 x A D ca. 3 x 1R 0.3 - 1.5 max. 30N 0.01/1 mm

E Shape acc. to DIN 8196

F 3 x toothdepth G 0.15 D

r/0 H optionallycounterprofil

A 1 mm C 0.2 D

35

II

!

!"#$

%

Design Guidelines II

1. Axial tool design: fixed fill volume considering the fill factor

2. General design guidelines

Limiting case for components with shoulder

Width / height ratio Shoulder thickness / length ratio

Max. overhang: ratio b / h 5 depending on:

the powders edge strength component density shoulder geometry

Factor 5 only applies to a rotary symmetrical shoulder without profile. All influences that increase wall friction (e.g. gear teeth) reduce possible overhang.

area

with

lo

wer

den

sity

area

with

lo

wer

den

sity

(ref. DIN 30912)

Avoid thin sections Apply radii

Avoid acute tangential tool transitions

0.025Tool partition

0.025Tool partition

36

Design Guidelines III

Original part drawing PM optimised solution

- all inner edges are rounded- tool edges meet at right angles- prevention of twisting by recesses in the contour

Tool structure

Upper punch Die and core rod Lower punch 1 Lower punch 2 Tool parts assembled

Tool split section

optimized geometry Alternative

3. Design guidelines for PM-tools, wire erosion technique prefered

37

II

Technical Support

In-house Tooling

The key to manufacturing high-performance, low-cost PM parts is the tool design. To meet customers most challeng-ing shape and dimensional requirements, GKN Sinter Met-als offers comprehensive in-house tooling capabilities, in-cluding all major 3D-specific software.

By customizing fixtures and die sets, GKN tailors tooling concepts to your specific applications. The result? Consid-erations of customers need to ensure exceptional tool wear and long-term tool life.

3D CAD/CAM Design Chain at GKN

Data Exchange with the customer for design via Electronic Data InterchangeAdditional technical conversation (meetings, calls) Finite Element Analysis to fit loading conditions vs. designGKN design of the part in Unigraphics (master model and drawing)Customer final check and approval before design freeze of model and drawingMaster model driven CAD parts for every following process step

3D Design of Tool Parts and Assembly

Tool assembly supported by 3D Design of PM relevant process steps Bill of material CAD-based Table of design driving parameters Image of set of parameters Table of dimensional behaviour Assembly of active powder touching tool parts Master model driven die set

CAD/CAM Transfer for Manufacturing and Inspec-tion of the Tools

PDM based administration of every component within the design area and tool departmentTransfer of CAD data to the tool shop for CAM based manufacturing of the toolsCMM evaluation of PM parts and tool components for PPAP and developmentCNC powder press for compaction of the component

CAD/CAM Design of Auxiliary Operations

Design of jigs and gauges Design of fully automated production including assem- bly steps if necessary

Finite Element Analysis at GKN Sinter Metals

Structural and mechanical FEA on parts and tool com- ponentsSimulation of linear elasticity, plasticity, static and dy- namic problemsProcess simulation as powder compaction Verification of results by experiments

38

Markets

GKN Sinter Metals serves both automotive and industrial/consumer markets worldwide. As more and more companies dis-cover the advantages of PM, our research and development team is hard at work leveraging years of product and process expertise to find all-new cost-effective applications for a host of industries.

Engine

Aluminium cam caps Bed plate inserts Connecting rods Main bearing caps Oil pump components Pulse rings Stainless flanges Timing system components

Interior Applications

Door & hatch lock mechanisms Rain sensor mounts Rearview mirror bosses Sunroof parts Window mechanisms

Steering Columns / Systems

Airbag components Ignition lock components Rotors, ratchets, levers, guides & yokes Pump components, gears & end plates Upper & lower tilt mechanisms Shift lock mechanisms Telescoping parts

Miscellaneous Applications

A/C compressor parts Alternator parts Bearings Bushings EGR valves Motor & drive parts Starter motor components Traction control system parts Wiper drive components Electronic stabilization package parts

Automatic Transmission

Backing and applied clutch plates Center and structural supports Clutch hubs Drive and driven sprockets Hydraulic pump parts Planetary carrier housings Powder forged one-way clutch races Specialty aluminium parts Tone wheels (for rpm sensing)

Braking Systems

ABS sensor wheels Adjusters Pistons Valve spacers & plates

Manual Transmission

Clutch hubs Shift fingers and assemblies Shift levers, latches and support plates Blocker guide pieces Clutch rings Cones Hubs Planetary carriers Rings (inner and outer)

Seating Systems

Adjustment gears Adjustment racks & levers Belt latch & tensioner parts

Exhaust Systems

Bosses Flanges

king and applied clutch platester and structural supportsch hubse and driven sprocketse and driven sprocketsraulic pump parts

netary carrier housingswder forged one-way clutch races

cialty aluminium partse wheels (for rpm sensing)

g Systems

sensor wheelsustersons

ve spacers & plates

Clutch hubs Shift fingers and assemblies Shift levers, latches and support plates Blocker guide piecesBlocker guide pieces Clutch rings Cones Hubs Planetary carriers Rings (inner and outer)

Seating Systems

Adjustment gears Adjustment racks & levers Belt latch & tensioner parts

Exhaust Systems

39

II

GKN Sinter Metals is committed to helping customers across a variety of markets manufacture at peak efficiency and lower overall costs. And, with the widest range of products, manufacturing capabilities and technical support in the PM industry, GKN is the single-source supplier of choice to the lawn and garden/outdoor power equipment, home appliance and office equipment, office and home furniture, and recreational vehicle markets, among others. Its key product lines include structural components, bushings, bearings, gears, pumps, metal injection molded (MIM) and powder forged parts.

Lawn and Garden Outdoor Power Equipment

In this category GKN supplies components as self-lubricating bearings, clutch plates, beveled gears, pumps and others.

Home and Office Appliances

GKN Sinter Metals is a leading supplier of transmission parts of large appli-ances such as washing machines. Also bearings and small structural compo-nents for blenders, food processors, other small appliances, copiers, print-ing machines and other consumer electronics belong to the product range.

Office and Home Furniture

In the growing furniture market, GKN Sinter Metals manufactures a variety of gear assemblies for home and office seating systems.

Recreational Vehicles

GKN applies PM technologies to manufacture clutch drive transmission systems for snowmobiles, four-wheelers, and all-terrain vehicles as well as pumps and more creative applications like binder clips for snowboards.PM components are also ideal for connecting rods, sensor rings and clutch hubs for motorcycles, scooters and boats.

Electronic and Power Tools

Small interacting parts, gears and bearings for drills, saws and other power electronic tools belong to the wide product range of GKN Sinter Metals.

Refrigeration

GKN Sinter Metals manufactures a variety of exacting parts like valve plates and compressor pistons for larger food refrigeration units and HVAC sys-tems.

40

GKN - Innovation by Research and Development

The idea of a center for research and development be-came reality with the construction of the GKN Technology Center in Radevormwald, Germany.

The central R & D facility for research into all areas of pow-der metallurgy covers an area of 3,500 m2.

From powder development to pilot production runs it is possible here to test and realize a great variety of options offered by powder metallurgy for the all-round service and support of our production plants and our customers. The GKN Technology Center is located in close vicinity to the most diverse production facilities applying powder metallurgy processes:

Powder forging, conventional press-and-sinter technol-ogy, Metal Injection Molding (MIM) and other advanced powder metal technologies.

41

II

State-of-the-art equipment and facilities are available.

In conjunction with the highly motivated staff of the GKN Technology Center they form the basis for the optimization of production-based process and product innovations.

New advanced technologies start out from here on a pro-found basis of fundamental research and secure emerg-ing new markets.

42

GKN - Innovation by Research and Development

A materials testing laboratory with full metallographic equipment like SEM and light microscopes allow specialists to investigate surfaces and microstructures and to deter-mine mechanical characteristics as well as chemical analy-sis. Corrosion testing is continued using a climate and a salt spray test chamber. A great variety of test procedures are thus available for investigations ranging from materials de-velopment to failure analysis, either for our own purposes or for our customers.

Resonance pulsers and modern cyclic bending machines are available for fatigue testing.

A Gammatec Densitometer is used for determination of the density.

Static and dynamic test methods are available for the deter-mination of soft magnetic characteristics.

Quality - QS Management

Quality management begins at the product concept stage and extends through design, pre-production planning and the entire product life cycle. It involves ongoing education programs, quality reporting and attention to detail every step of the way.

At GKN Sinter Metals quality is a multidisciplinary responsibility and highest priority for each employee.

GKN Sinter Metals Certifications:

ISO 9001ISO/TS 16949

ISO 14001OHSAS 18001

Ford Q1

43

II

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Notes

Copyright 2014, GKN Sinter Metals

GKNSinterMetals.com

GLOBAL SALES OFFICES GKN Locations

30 Production Facilities in 14 Countries on 5 ContinentsFor specific details and contact information concerning our production facilities, go to GKNSinterMetals.com.

AMERICAS USA 2200 N. Opdyke Road Auburn Hills, MI 48326-2431 infona@gknsintermetals.com

Brazil Av. Emancipao, 4.500 CEP 13186-542 Hortolandia SP, Brazil infobrazil@gknsintermetals.com

ASIA China Suite 1105-1110, POS Plaza 1600 Century Avenue Pudong, Shanghai 200122, China infochina@gknsintermetals.com

India 146 Mumbai - Pune Road Pimpri, Pune 411018 Maharashtra, India infoindia@gknsintermetals.com

Japan Senri Life Science Center Bldg.10F 1-4-2 ShinSenri Higashi-machi Toyonaka-city, Osaka, 560-0082 Japan infojapan@gknsintermetals.com

AFRICASouth AfricaP.O. Box 156, Sacks CircleBellville 7530, South Africainfoafrica@gknsintermetals.com

EUROPE United Kingdom Nottingham, United Kingdom P.O. Box 9211 Nottingham, NG10 9BD, England infoengland@gknsintermetals.com

Germany Krebsge 10 42 477 Radevormwald, Germany infogermany@gknsintermetals.com

Italy Fabrikstrae 5 39 031 Bruneck (BZ), Italy infoitaly@gknsintermetals.com

Sweden Mlndal, Sweden P.O. Box 186, SE-431 23 Mlndal, Sweden infosweden@gknsintermetals.com

France 6 Lotissement les Cruzettes 38210 Tullins, France infofrance@gknsintermetals.com

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