EP1554071B1 - Method of preparing iron-based components by compaction with elevated pressures - Google Patents
Method of preparing iron-based components by compaction with elevated pressures Download PDFInfo
- Publication number
- EP1554071B1 EP1554071B1 EP03751717A EP03751717A EP1554071B1 EP 1554071 B1 EP1554071 B1 EP 1554071B1 EP 03751717 A EP03751717 A EP 03751717A EP 03751717 A EP03751717 A EP 03751717A EP 1554071 B1 EP1554071 B1 EP 1554071B1
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- European Patent Office
- Prior art keywords
- powder
- compaction
- process according
- particles
- iron
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 37
- 238000005056 compaction Methods 0.000 title claims abstract description 27
- 229910052742 iron Inorganic materials 0.000 title claims abstract description 21
- 239000000843 powder Substances 0.000 claims abstract description 76
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 9
- 239000010439 graphite Substances 0.000 claims abstract description 9
- 238000002360 preparation method Methods 0.000 claims abstract description 4
- 238000002156 mixing Methods 0.000 claims abstract description 3
- 239000002245 particle Substances 0.000 claims description 41
- 239000000314 lubricant Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 5
- 238000005245 sintering Methods 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 229910052758 niobium Inorganic materials 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 229910052720 vanadium Inorganic materials 0.000 claims description 3
- 230000002708 enhancing effect Effects 0.000 claims description 2
- 239000010419 fine particle Substances 0.000 abstract description 6
- 239000000654 additive Substances 0.000 abstract description 4
- 239000000203 mixture Substances 0.000 description 21
- 229910000831 Steel Inorganic materials 0.000 description 9
- 239000010959 steel Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 7
- 238000005461 lubrication Methods 0.000 description 5
- 230000005291 magnetic effect Effects 0.000 description 5
- 239000011362 coarse particle Substances 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 238000005275 alloying Methods 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- RKISUIUJZGSLEV-UHFFFAOYSA-N n-[2-(octadecanoylamino)ethyl]octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(=O)NCCNC(=O)CCCCCCCCCCCCCCCCC RKISUIUJZGSLEV-UHFFFAOYSA-N 0.000 description 2
- 238000009527 percussion Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- -1 atomised iron powder Chemical compound 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical class [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 239000002923 metal particle Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- 238000007514 turning Methods 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
- B22F2003/023—Lubricant mixed with the metal powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
- B22F2003/026—Mold wall lubrication or article surface lubrication
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
Definitions
- the present invention concerns a method for the preparation of components having high density by using metal powder compositions useful within the powder metallurgical industry.
- the invention is defined in claims 1-10.
- the powder forging process has the advantage that full dense components may be obtained.
- the process is however costly and is utilised mainly for mass production of heavier components, such as connection rods.
- Full dense materials can also be obtained by elevated pressures at high temperatures, such as in hot isostatic pressing, HIP, but also this method is costly.
- warm compaction a process where the compaction is performed at an elevated temperature, typically at 120 to 250 °C, the density can be increased with about 0,2 g/cm 3 , which results in a considerable improvement of the mechanical properties.
- a disadvantage is however that the warm compaction method involves additional investment and processing. Other processes, such as double pressing, double sintering, sintering at elevated temperatures etc, may further increase the density. Also these methods will add further production costs hence reducing the overall cost effectiveness.
- the method according to the present invention includes the steps of providing an iron-based powder essentially free from fine particles; optionally mixing said powder with graphite and other additives; uniaxially compacting the powder in a die at high pressure and ejecting the green body, which may subsequently be sintered.
- high density is intended to mean compacts having a density of about at least 7.3 g/cm 3 .
- Components having lower densities can of course also be produced but are believed to be of less interest.
- the iron-based powder according to the present invention includes pure iron powder such as atomised iron powder, sponge iron powder, reduced iron powder; partially diffusion-alloyed steel powder; and completely alloyed steel powder.
- the partially diffusion-alloyed steel powder is preferably a steel powder alloyed partially with one or more of Cu, Ni, and Mo.
- the completely alloyed steel powder is preferably a steel powder alloyed with Mn, Cu, Ni, Cr, Mo, V, Co, W, Nb, Ti, Al, P, S and B. Also stainless steel powders are of interest.
- the particles have an irregular form as is obtained by water atomisation. Also sponge iron powders having irregularly shaped particles may be of interest.
- a critical feature of the invention is that the powder used have coarse particles i.e. the powder is essentially without fine particles.
- the term "essentially without fine particles” is intended to mean that less than about 5 % of the powder particles have a size below 45 ⁇ m as measured by the method described in SS-EN 24 497. So far the most interesting results have been achieved with powders essentially consisting of particles above about 106 ⁇ m and particularly above about 212 ⁇ m.
- the term "essentially consists” is intended to mean that at least 50 %, preferably at least 60 %, and most preferably at least 70 % of the particles have a particle size above 106 and 212 ⁇ m, respectively.
- the maximum particle size may be about 2 mm.
- the particle size distribution for iron-based powders used at PM manufacturing is normally distributed with a gaussian distribution with a average particle diameter in the region of 30 to 100 ⁇ m and about 10-30 % less than 45 ⁇ m.
- Iron based powders essentially free from fine particles may be obtained by removing the finer fractions of the powder or by manufacturing a powder having the desired particle size distribution.
- Powders having coarse particles are also used for the manufacture of soft magnetic components.
- US patent 6 309 748 discloses a ferromagnetic powder, the particles of which have a diameter size between 40 and 600 ⁇ m.
- these powder particles are provided with a coating.
- the iron powder includes particles with less than 5 % exceeding 417 ⁇ m, and less than about 20 % of the powder particles have a size less than 147 ⁇ m.
- This patent teaches that, because of the very low content of particles less than 147 ⁇ m, the mechanical properties of components manufactured from this coarse, highly pure powder are very low.
- this powder teaches that if higher strength is desired, it is not possible to increase the content of particles having a size less than 147 ⁇ m without simultaneously deteriorating the soft magnetic properties. Therefore this powder is mixed with specific amounts of ferrophosphorus.
- Graphite which may be used in the compositions according to the present invention is not mentioned in this patent and besides the presence of graphite would deteriorate the magnetic properties.
- Powder mixtures including coarse particles are also disclosed in the US patent 5225459 ( EP 554 009 ) which also concerns powder mixtures for the preparation of soft magnetic components. Nor do these powder mixtures include graphite.
- additives may be added to the iron-based powder before compaction, such as alloying elements comprising Mn, Cu, Ni, Cr, Mo, V, Co, W, Nb, Ti, Al, P, S, and B. These alloying elements may be added in amounts up to 10 % by weight. Further additives are machinability enhancing compounds, hard phase material and flow agents.
- the iron-base powder may also be combined with a lubricant before it is transferred to the die (internal lubrication).
- the lubricant is added to minimize friction between the metal power particles and between the particles and the die during a compaction, or pressing, step.
- suitable lubricants are e.g. stearates, waxes, fatty acids and derivatives thereof, oligomers, polymers and other organic substances with lubricating effect.
- the lubricants are preferably added in the form of particles but may also be bonded and/or coated to the particles. According to the present invention the amount of lubricant added to the iron-based powder may vary between 0.05 and 0.6 %, preferably between 0.1-0.5 % by weight of the mixture.
- the method according to the invention may also be performed with the use of external lubrication (die wall lubrication) where the walls of the die are provided with a lubricant before the compaction is performed.
- external lubrication die wall lubrication
- a combination of external and internal lubrication may also be used.
- At high compaction pressure is intended to mean at pressures of about at least 800 MPa. More interesting results are obtained with higher pressures such as pressures above 900, preferably above 1000, more preferably above 1100 MPa.
- the compaction may be performed with standard equipment, which means that the new method may be performed without expensive investments.
- the compaction is performed uniaxially in a single step at ambient or elevated temperature.
- the compaction may be performed with the aid of a percussion machine (Model HYP 35-4 from Hydropulsor) as described in patent publication WO 02/38315 .
- the sintering may be performed at temperatures normally used within the PM field, e.g. at standard temperature between 1080 and 1160C°C or at higher temperatures above 1160°C and in conventionally used atmospheres.
- the advantages obtained by using the method according to the present invention are that high density green compacts can be cost effectively produced.
- the new method also permits production of higher components which are difficult to produce by using the conventional technique.
- standard compaction equipment can be used for producing high density compacts having acceptable or even perfect surface finish.
- Examples of products which suitably can be manufactured by the new method are connecting rods, gears and other structural parts subjected to high loads.
- By using stainless steel powders flanges are of special interest.
- Two different iron-based powder compositions according to the present invention were compared with a standard iron-based powder composition. All three compositions were produced with Astaloy Mo available from Höganäs AB, Sweden. 0.2 % by weight of graphite and 0.4 % by weight of a lubricant (KenolubeTM) were added to the compositions. In one of the iron-based powder compositions according to the invention, particles of the Astaloy Mo with a diameter less than 45 ⁇ m were removed and in the other composition according to the invention particles of Astaloy Mo less than 212 ⁇ m were removed. The compaction was performed at ambient temperature and in standard equipment. As can be seen from figure 1-1 a clear density increase at all compaction pressures is obtained with the powder having a particle size above 212 ⁇ m.
- Figure 1-2 shows that in order to obtain components without deteriorated surfaces the most important factor is the reduction or elimination of the smallest particles, i.e. particles below 45 ⁇ m. Furthermore from this figure it can be seen that the force needed for ejection of the compacts produced by the iron based powder composition without particles less than 212 ⁇ m was considerably reduced compared with the ejection force needed for compacts produced from the standard iron-based powder composition having about 20 % of the particles less than 45 ⁇ m. The ejection force needed for compacts produced from the iron-based powder composition according to the invention without particles less than 45 ⁇ m is also reduced in comparison with the standard powder.
- a noticeable phenomenon is that the ejection force for compacts produced according to the present invention decreases with the increasing ejection pressure whereas the opposite is valid for the standard composition.
- Example 1 was repeated but as lubricant 0.5 % of EBS (ethylene bisstearamide) was used and the compaction was performed with the aid of a percussion machine (Model HYP 35-4 from Hydropulsor, Sweden)
- EBS ethylene bisstearamide
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Powder Metallurgy (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Treatment Of Steel In Its Molten State (AREA)
- Manufacture Of Iron (AREA)
Abstract
Description
- The present invention concerns a method for the preparation of components having high density by using metal powder compositions useful within the powder metallurgical industry. The invention is defined in claims 1-10.
- There are several advantages by using powder metallurgical methods for producing structural parts compared with conventional matching processes of full dense steel. Thus, the energy consumption is much lower and the material utilisation is much higher. Another important factor in favour of the powder metallurgical route is that components with net shape or near net shape can be produced directly after the sintering process without costly shaping processes such as turning, milling, boring or grinding. However, normally a full dense steel material has superior mechanical properties compared with PM components. This is mainly due to the occurrence of porosity in the PM components. Therefore, the strive has been to increase the density of PM components in order to reach values as close as possible to the density value of a full dense steel.
- Among the methods used in order to reach higher density of PM components the powder forging process has the advantage that full dense components may be obtained. The process is however costly and is utilised mainly for mass production of heavier components, such as connection rods. Full dense materials can also be obtained by elevated pressures at high temperatures, such as in hot isostatic pressing, HIP, but also this method is costly.
- By using warm compaction, a process where the compaction is performed at an elevated temperature, typically at 120 to 250 °C, the density can be increased with about 0,2 g/cm3, which results in a considerable improvement of the mechanical properties. A disadvantage is however that the warm compaction method involves additional investment and processing. Other processes, such as double pressing, double sintering, sintering at elevated temperatures etc, may further increase the density. Also these methods will add further production costs hence reducing the overall cost effectiveness.
- In order to expand the market for powder metallurgical components and utilise the advantages with the powder metallurgical technique there is thus a need for a simple, less expensive method of achieving high density compacts with improved static and dynamic mechanical strength.
- It has now been found that high density components can be obtained by using high compaction pressures in combination with coarse powders. In view of the general knowledge, that conventionally used powders, i.e. powders including fine particles, cannot be compacted to high densities without problems with e.g. damaged or deteriorated surfaces of the compacts this finding is quite unexpected. Specifically, the method according to the present invention includes the steps of providing an iron-based powder essentially free from fine particles; optionally mixing said powder with graphite and other additives; uniaxially compacting the powder in a die at high pressure and ejecting the green body, which may subsequently be sintered.
- The term " high density" is intended to mean compacts having a density of about at least 7.3 g/cm3. Components having lower densities can of course also be produced but are believed to be of less interest.
- The iron-based powder according to the present invention includes pure iron powder such as atomised iron powder, sponge iron powder, reduced iron powder; partially diffusion-alloyed steel powder; and completely alloyed steel powder. The partially diffusion-alloyed steel powder is preferably a steel powder alloyed partially with one or more of Cu, Ni, and Mo. The completely alloyed steel powder is preferably a steel powder alloyed with Mn, Cu, Ni, Cr, Mo, V, Co, W, Nb, Ti, Al, P, S and B. Also stainless steel powders are of interest.
- As regards the particle shape it is preferred that the particles have an irregular form as is obtained by water atomisation. Also sponge iron powders having irregularly shaped particles may be of interest.
- A critical feature of the invention is that the powder used have coarse particles i.e. the powder is essentially without fine particles. The term "essentially without fine particles" is intended to mean that less than about 5 % of the powder particles have a size below 45 µm as measured by the method described in SS-EN 24 497. So far the most interesting results have been achieved with powders essentially consisting of particles above about 106 µm and particularly above about 212 µm. The term "essentially consists" is intended to mean that at least 50 %, preferably at least 60 %, and most preferably at least 70 % of the particles have a particle size above 106 and 212 µm, respectively. The maximum particle size may be about 2 mm. The particle size distribution for iron-based powders used at PM manufacturing is normally distributed with a gaussian distribution with a average particle diameter in the region of 30 to 100 µm and about 10-30 % less than 45 µm. Iron based powders essentially free from fine particles may be obtained by removing the finer fractions of the powder or by manufacturing a powder having the desired particle size distribution.
- The influence of particle size distribution and the influence of particle shape on the compaction properties and properties of the compacted body have been subjected to intense studies. Thus the
US patent 5,594,186 reveals a method of producing PM components with a density higher than 95 % of theoretical density by utilising substantially linear, acicular metal particles having a triangular cross section. Such particles are suitably produced by a machining or milling process. - Powders having coarse particles are also used for the manufacture of soft magnetic components. Thus the
US patent 6 309 748 discloses a ferromagnetic powder, the particles of which have a diameter size between 40 and 600 µm. In contrast to iron based powder particles according to the present invention, these powder particles are provided with a coating. - In the
US patent 4,190,441 a powder composition for production of sintered soft magnetic components is disclosed. In this patent the iron powder includes particles with less than 5 % exceeding 417 µm, and less than about 20 % of the powder particles have a size less than 147 µm. This patent teaches that, because of the very low content of particles less than 147 µm, the mechanical properties of components manufactured from this coarse, highly pure powder are very low. Furthermore the patent teaches that if higher strength is desired, it is not possible to increase the content of particles having a size less than 147 µm without simultaneously deteriorating the soft magnetic properties. Therefore this powder is mixed with specific amounts of ferrophosphorus. Graphite which may be used in the compositions according to the present invention is not mentioned in this patent and besides the presence of graphite would deteriorate the magnetic properties. - Powder mixtures including coarse particles are also disclosed in the
US patent 5225459 (EP 554 009 - Within the field of powder forging it is furthermore known that pre-alloyed iron-based powders with coarse particles can be used. The
US patent 3 901 661 discloses such powders. This patent discloses that a lubricant may be included and specifically that the amount of lubricant should be 1 % by weight (example 1). If the powders according to the present invention were mixed with such a high amount of lubricant it would however not be possible to achieve the high densities. - In order to obtain compacts having satisfactory mechanical sintered properties of the sintered part according to the present invention it is necessary to add certain amounts of graphite to the powder mixture to be compacted. Thus graphite in amounts between 0.1-1, preferably 0.2 -1.0 and most preferably 0.2-0.8 % by weight of the total mixture to be compacted could be added before the compaction.
- Other additives may be added to the iron-based powder before compaction, such as alloying elements comprising Mn, Cu, Ni, Cr, Mo, V, Co, W, Nb, Ti, Al, P, S, and B. These alloying elements may be added in amounts up to 10 % by weight. Further additives are machinability enhancing compounds, hard phase material and flow agents.
- The iron-base powder may also be combined with a lubricant before it is transferred to the die (internal lubrication). The lubricant is added to minimize friction between the metal power particles and between the particles and the die during a compaction, or pressing, step. Examples of suitable lubricants are e.g. stearates, waxes, fatty acids and derivatives thereof, oligomers, polymers and other organic substances with lubricating effect. The lubricants are preferably added in the form of particles but may also be bonded and/or coated to the particles. According to the present invention the amount of lubricant added to the iron-based powder may vary between 0.05 and 0.6 %, preferably between 0.1-0.5 % by weight of the mixture.
- The method according to the invention may also be performed with the use of external lubrication (die wall lubrication) where the walls of the die are provided with a lubricant before the compaction is performed. A combination of external and internal lubrication may also be used.
- The term "at high compaction pressure" is intended to mean at pressures of about at least 800 MPa. More interesting results are obtained with higher pressures such as pressures above 900, preferably above 1000, more preferably above 1100 MPa.
- Conventional compaction at high pressures, i.e. pressures above about 800 MPa with conventionally used powders including finer particles, in admixture with low amounts of lubricants (less than 0.6 % by weight) are generally considered unsuitable due to the high forces required in order to eject the compacts from the die, the accompanying high wear of the die and the fact that the surfaces of the components tend to be less shiny or deteriorated. By using the powders according to the present invention it has unexpectedly been found that the ejection force is reduced at high pressures, about 1000 MPa, and that components having acceptable or even perfect surfaces may be obtained also when die wall lubrication is not used.
- The compaction may be performed with standard equipment, which means that the new method may be performed without expensive investments. The compaction is performed uniaxially in a single step at ambient or elevated temperature. Alternatively the compaction may be performed with the aid of a percussion machine (Model HYP 35-4 from Hydropulsor) as described in patent publication
WO 02/38315 - The sintering may be performed at temperatures normally used within the PM field, e.g. at standard temperature between 1080 and 1160C°C or at higher temperatures above 1160°C and in conventionally used atmospheres.
- Other treatments of the green or sintered component may as well be applied, such as machining, case hardening, surface densification or other methods used in PM technology.
- In brief the advantages obtained by using the method according to the present invention are that high density green compacts can be cost effectively produced. The new method also permits production of higher components which are difficult to produce by using the conventional technique. Additionally standard compaction equipment can be used for producing high density compacts having acceptable or even perfect surface finish.
- Examples of products which suitably can be manufactured by the new method are connecting rods, gears and other structural parts subjected to high loads. By using stainless steel powders flanges are of special interest.
- The invention is further illustrated by the following examples.
- Two different iron-based powder compositions according to the present invention were compared with a standard iron-based powder composition. All three compositions were produced with Astaloy Mo available from Höganäs AB, Sweden. 0.2 % by weight of graphite and 0.4 % by weight of a lubricant (Kenolube™) were added to the compositions. In one of the iron-based powder compositions according to the invention, particles of the Astaloy Mo with a diameter less than 45 µm were removed and in the other composition according to the invention particles of Astaloy Mo less than 212 µm were removed. The compaction was performed at ambient temperature and in standard equipment. As can be seen from
figure 1-1 a clear density increase at all compaction pressures is obtained with the powder having a particle size above 212µm. -
Figure 1-2 shows that in order to obtain components without deteriorated surfaces the most important factor is the reduction or elimination of the smallest particles, i.e. particles below 45 µm. Furthermore from this figure it can be seen that the force needed for ejection of the compacts produced by the iron based powder composition without particles less than 212µm was considerably reduced compared with the ejection force needed for compacts produced from the standard iron-based powder composition having about 20 % of the particles less than 45µm. The ejection force needed for compacts produced from the iron-based powder composition according to the invention without particles less than 45µm is also reduced in comparison with the standard powder. - A noticeable phenomenon is that the ejection force for compacts produced according to the present invention decreases with the increasing ejection pressure whereas the opposite is valid for the standard composition.
- It was also observed that the compacts obtained when the standard powder was compacted at a pressure above 700 MPa had deteriorated surfaces and were accordingly not acceptable. The compacts, which were obtained when the powder essentially without particles less than 45 µm was compacted at a pressure above 700 MPa, had a less shiny surface which at least under certain circumstances is acceptable.
- Example 1 was repeated but as lubricant 0.5 % of EBS (ethylene bisstearamide) was used and the compaction was performed with the aid of a percussion machine (Model HYP 35-4 from Hydropulsor, Sweden)
- From
figure 2-1 and 2-2 , respectively, it can be noticed that higher green densities and lower ejection forces were obtained with the powder composition according to the invention compared with the powder composition with the standard powder. It can also be noticed that components produced from the standard powder had deteriorated surfaces at all compaction pressures.
Claims (10)
- Process for the preparation of high density green compacts comprising the following steps:providing an atomised iron-based powder, optionally comprising Mn, Cu, Ni, Cr, Mo, V, Co, W, Nb, Ti, Al, P, S and B, wherein less than 5% of the iron-based powder particles have a size below 45 µm;mixing said powder with 0.1-1.0% by weight graphite and a lubricant in an amount between 0.05 and 0.6% by weight, optionally machinability enhancing agents, hard phase materials and flow agents;uniaxially compacting the powder in a die at a compaction pressure of at least 800 MPa; andejecting the green body from the die.
- Process according to claim 1, wherein the compaction is performed in a single step.
- Process according to claim 1 or 2, wherein at least 50%, preferably at least 60% and most preferably at least 70% of the iron-based powder consists of particles having a particle size above 106 µm.
- Process according to any one of the claims 1-3, wherein at least 50%, preferably at least 60% and most preferably at least 70% of the iron-based powder consists of particles having a particle size above 212 µm.
- Process according to claim 4, wherein the maximum particle size is 2 mm.
- Process according to any one of claims 1-5, wherein the compaction is performed in a lubricated die.
- Process according to any one of claims 1-6, wherein the compaction is performed at a pressure of at least 900 MPa, more preferably at least 1000 MPa and most preferably above 1100 MPa.
- Process according to any one of claims 1-7, wherein the compaction is performed at ambient temperature.
- Process according to any one of claims 1-8, wherein the compaction is performed at elevated temperature.
- Process according to any one of claims 1-9 for preparing sintered products, said process further including a single sintering step at a temperature above 1100°C.
Applications Claiming Priority (3)
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SE0203134 | 2002-10-22 | ||
SE0203134A SE0203134D0 (en) | 2002-10-22 | 2002-10-22 | Method of preparing iron-based components |
PCT/SE2003/001633 WO2004037468A1 (en) | 2002-10-22 | 2003-10-22 | Method of preparing iron-based components by compaction with elevated pressures |
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EP1554071A1 EP1554071A1 (en) | 2005-07-20 |
EP1554071B1 true EP1554071B1 (en) | 2010-12-08 |
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EP03751717A Expired - Lifetime EP1554071B1 (en) | 2002-10-22 | 2003-10-22 | Method of preparing iron-based components by compaction with elevated pressures |
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EP (1) | EP1554071B1 (en) |
JP (2) | JP4909514B2 (en) |
KR (2) | KR20050059285A (en) |
CN (1) | CN1705533B (en) |
AT (1) | ATE490830T1 (en) |
AU (1) | AU2003269786B2 (en) |
BR (1) | BR0314079B1 (en) |
CA (1) | CA2495697C (en) |
DE (1) | DE60335280D1 (en) |
ES (1) | ES2357741T3 (en) |
MX (1) | MXPA05004256A (en) |
PL (1) | PL208668B1 (en) |
RU (1) | RU2333075C2 (en) |
SE (1) | SE0203134D0 (en) |
TW (2) | TW201127521A (en) |
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TWI328236B (en) * | 2005-06-15 | 2010-08-01 | Hoganas Ab Publ | Process for the manufacture of soft magnetic composite components and soft magnetic composite components obtained therefrom |
KR100978901B1 (en) * | 2008-03-21 | 2010-08-31 | 가야에이엠에이 주식회사 | MANUFACTURING METHOD OF Fe-BASED SINTERED BODY WITH HIGH TENSILE STRENGTH AND HIGH HARDNESS |
CA2798516C (en) * | 2010-05-19 | 2017-03-14 | Hoeganaes Corporation | Compositions and methods for improved dimensional control in ferrous powder metallurgy applications |
WO2013122873A1 (en) * | 2012-02-15 | 2013-08-22 | Gkn Sinter Metals, Llc | Powder metal with solid lubricant and powder metal scroll compressor made therefrom |
JP5903738B2 (en) * | 2012-03-29 | 2016-04-13 | 住友電工焼結合金株式会社 | Method for producing ferrous sintered alloy |
EP2743361A1 (en) * | 2012-12-14 | 2014-06-18 | Höganäs AB (publ) | New product and use thereof |
RU2588979C1 (en) * | 2015-03-16 | 2016-07-10 | Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Кубанский государственный технологический университет" (ФГБОУ ВПО "КубГТУ") | Method of producing high-density powder chromium containing material based on iron |
AT526261B1 (en) * | 2022-07-05 | 2024-03-15 | Miba Sinter Austria Gmbh | Method for producing a component from a sinter powder |
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US3901661A (en) * | 1972-04-06 | 1975-08-26 | Toyo Kohan Co Ltd | Prealloyed steel powder for formation of structural parts by powder forging and powder forged article for structural parts |
JPS5230924B2 (en) * | 1972-04-06 | 1977-08-11 | ||
US4190441A (en) * | 1978-03-02 | 1980-02-26 | Hoganas Ab Fack | Powder intended for powder metallurgical manufacturing of soft magnetic components |
SU882702A1 (en) * | 1979-02-28 | 1981-11-23 | Научно-Исследовательский Институт Порошковой Металлургии Белорусского Ордена Трудового Красного Знамени Политехнического Института | Method of producing sintered fe-based articles |
SU872028A1 (en) * | 1979-12-17 | 1981-10-15 | Московский Ордена Трудового Красного Знамени Институт Тонкой Химической Технологии Им.М.В.Ломоносова | Metallic powder pressing method |
JPS61183444A (en) * | 1985-02-08 | 1986-08-16 | Toyota Motor Corp | High strength sintered alloy and its manufacture |
US5225459A (en) * | 1992-01-31 | 1993-07-06 | Hoeganaes Corporation | Method of making an iron/polymer powder composition |
US5154881A (en) * | 1992-02-14 | 1992-10-13 | Hoeganaes Corporation | Method of making a sintered metal component |
US5594186A (en) * | 1995-07-12 | 1997-01-14 | Magnetics International, Inc. | High density metal components manufactured by powder metallurgy |
GB2315115B (en) | 1996-07-10 | 2000-05-31 | Hitachi Powdered Metals | Valve guide |
US5872322A (en) * | 1997-02-03 | 1999-02-16 | Ford Global Technologies, Inc. | Liquid phase sintered powder metal articles |
US5892164A (en) * | 1997-03-19 | 1999-04-06 | Air Products And Chemicals, Inc. | Carbon steel powders and method of manufacturing powder metal components therefrom |
JP3462378B2 (en) * | 1997-11-07 | 2003-11-05 | 日立粉末冶金株式会社 | Powder molding method in powder metallurgy |
US5982073A (en) * | 1997-12-16 | 1999-11-09 | Materials Innovation, Inc. | Low core loss, well-bonded soft magnetic parts |
JP3869620B2 (en) * | 1999-04-16 | 2007-01-17 | 株式会社日立製作所 | Alloy steel powder molding material, alloy steel powder processed body, and manufacturing method of alloy steel powder molding material |
EP1145788B1 (en) * | 1999-10-29 | 2004-12-15 | JFE Steel Corporation | Lubricating agent for mold at elevated temperature and method for producing high density iron-based sintered compact |
SE0004122D0 (en) * | 2000-11-09 | 2000-11-09 | Hoeganaes Ab | High density compacts and method for the preparation thereof |
JP4078512B2 (en) * | 2001-04-20 | 2008-04-23 | Jfeスチール株式会社 | Highly compressible iron powder |
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RU2005115474A (en) | 2005-10-27 |
TW200417433A (en) | 2004-09-16 |
ZA200501296B (en) | 2006-10-25 |
PL375094A1 (en) | 2005-11-14 |
RU2333075C2 (en) | 2008-09-10 |
TW201127521A (en) | 2011-08-16 |
AU2003269786B2 (en) | 2007-12-13 |
KR101179725B1 (en) | 2012-09-04 |
WO2004037468A1 (en) | 2004-05-06 |
JP4909514B2 (en) | 2012-04-04 |
JP2010189769A (en) | 2010-09-02 |
CN1705533A (en) | 2005-12-07 |
CA2495697C (en) | 2011-12-13 |
BR0314079B1 (en) | 2011-10-04 |
ES2357741T3 (en) | 2011-04-29 |
CA2495697A1 (en) | 2004-05-06 |
AU2003269786A1 (en) | 2004-05-13 |
MXPA05004256A (en) | 2005-07-05 |
KR20050059285A (en) | 2005-06-17 |
JP2006503983A (en) | 2006-02-02 |
ATE490830T1 (en) | 2010-12-15 |
BR0314079A (en) | 2005-07-05 |
KR20110114689A (en) | 2011-10-19 |
EP1554071A1 (en) | 2005-07-20 |
PL208668B1 (en) | 2011-05-31 |
CN1705533B (en) | 2010-08-11 |
TWI415698B (en) | 2013-11-21 |
DE60335280D1 (en) | 2011-01-20 |
SE0203134D0 (en) | 2002-10-22 |
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