EP1554071B1 - Procede de preparation de composants a base de fer par compactage a des pressions elevees - Google Patents

Procede de preparation de composants a base de fer par compactage a des pressions elevees Download PDF

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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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EP
European Patent Office
Prior art keywords
powder
compaction
process according
particles
iron
Prior art date
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.)
Expired - Lifetime
Application number
EP03751717A
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German (de)
English (en)
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EP1554071A1 (fr
Inventor
Mikhail Kejzelman
Paul Skoglund
Hilmar Vidarsson
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Hoganas AB
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Hoganas AB
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Filing date
Publication date
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Publication of EP1554071A1 publication Critical patent/EP1554071A1/fr
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Publication of EP1554071B1 publication Critical patent/EP1554071B1/fr
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    • 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)

Claims (10)

  1. Procédé de préparation de comprimés crus à haute densité comprenant les étapes suivantes :
    fournir une poudre pulvérisée à base de fer, comprenant facultativement Mn, Cu, Ni, Cr, Mo, V, Co, W, Nb, Ti, Al, P, S et B,
    dans laquelle moins de 5 % des particules de poudre à base de fer ont une taille inférieure à 45 µm ;
    mélanger ladite poudre avec 0,1 à 1,0 % en masse de graphite et d'un lubrifiant dans une quantité comprise entre 0,05 et 0,6 % en masse,
    facultativement des agents favorisant l'usinabilité, des matériaux à phase dure et des agents d'écoulement ;
    compacter de façon uniaxiale la poudre dans une filière à une pression de compactage d'au moins 800 MPa ; et
    éjecter l'ébauche crue de la filière.
  2. Procédé selon la revendication 1, dans lequel le compactage est effectué au cours d'une seule étape.
  3. Procédé selon la revendication 1 ou 2, dans lequel au moins 50 %, de préférence au moins 60 % et le plus préférablement au moins 70 % de la poudre à base de fer sont constitués de particules ayant une taille des particules supérieure à 106 µm.
  4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel au moins 50 %, de préférence au moins 60 % et le plus préférablement au moins 70 % de la poudre à base de fer sont constitués de particules ayant une taille des particules supérieure à 212 µm.
  5. Procédé selon la revendication 4, dans lequel la taille maximale des particules est de 2 mm.
  6. Procédé selon l'une quelconque des revendications 1 à 5, dans lequel le compactage est effectué dans une filière lubrifiée.
  7. Procédé selon l'une quelconque des revendications 1 à 6, dans lequel le compactage est effectué à une pression d'au moins 900 MPa, plus préférablement d'au moins 1 000 MPa et le plus préférablement d'au moins 1 100 MPa.
  8. Procédé selon l'une quelconque des revendications 1 à 7, dans lequel le compactage est effectué à température ambiante.
  9. Procédé selon l'une quelconque des revendications 1 à 8, dans lequel le compactage est effectué à température élevée.
  10. Procédé selon l'une quelconque des revendications 1 à 9, pour préparer des produits frittés, ledit procédé incluant également une seule étape de frittage à une température supérieure à 1 100 °C.
EP03751717A 2002-10-22 2003-10-22 Procede de preparation de composants a base de fer par compactage a des pressions elevees Expired - Lifetime EP1554071B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
SE0203134A SE0203134D0 (sv) 2002-10-22 2002-10-22 Method of preparing iron-based components
SE0203134 2002-10-22
PCT/SE2003/001633 WO2004037468A1 (fr) 2002-10-22 2003-10-22 Procede de preparation de composants a base de fer par compactage a des pressions elevees

Publications (2)

Publication Number Publication Date
EP1554071A1 EP1554071A1 (fr) 2005-07-20
EP1554071B1 true EP1554071B1 (fr) 2010-12-08

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EP03751717A Expired - Lifetime EP1554071B1 (fr) 2002-10-22 2003-10-22 Procede de preparation de composants a base de fer par compactage a des pressions elevees

Country Status (17)

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EP (1) EP1554071B1 (fr)
JP (2) JP4909514B2 (fr)
KR (2) KR101179725B1 (fr)
CN (1) CN1705533B (fr)
AT (1) ATE490830T1 (fr)
AU (1) AU2003269786B2 (fr)
BR (1) BR0314079B1 (fr)
CA (1) CA2495697C (fr)
DE (1) DE60335280D1 (fr)
ES (1) ES2357741T3 (fr)
MX (1) MXPA05004256A (fr)
PL (1) PL208668B1 (fr)
RU (1) RU2333075C2 (fr)
SE (1) SE0203134D0 (fr)
TW (2) TWI415698B (fr)
WO (1) WO2004037468A1 (fr)
ZA (1) ZA200501296B (fr)

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PL1899994T3 (pl) * 2005-06-15 2018-01-31 Hoeganaes Ab Magnetycznie miękkie materiały kompozytowe
KR100978901B1 (ko) * 2008-03-21 2010-08-31 가야에이엠에이 주식회사 고인장강도 및 고경도를 가지는 철계 소결체 제조 방법
CN102947028B (zh) * 2010-05-19 2015-09-02 赫格纳斯公司 铁粉冶金应用中用于改进的尺寸控制的组合物和方法
DE112013000990T5 (de) * 2012-02-15 2015-04-09 Gkn Sinter Metals, Llc. Pulvermetall mit Festschmierstoff und ein daraus hergestellter Pulvermetallscrollverdichter
JP5903738B2 (ja) * 2012-03-29 2016-04-13 住友電工焼結合金株式会社 鉄系焼結合金の製造方法
EP2743361A1 (fr) * 2012-12-14 2014-06-18 Höganäs AB (publ) Nouveau produit et usage correspondant
RU2588979C1 (ru) * 2015-03-16 2016-07-10 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Кубанский государственный технологический университет" (ФГБОУ ВПО "КубГТУ") Способ получения высокоплотного порошкового хромсодержащего материала на основе железа
AT526261B1 (de) * 2022-07-05 2024-03-15 Miba Sinter Austria Gmbh Verfahren zur Herstellung eines Bauteils aus einem Sinterpulver

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Also Published As

Publication number Publication date
ES2357741T3 (es) 2011-04-29
JP4909514B2 (ja) 2012-04-04
KR101179725B1 (ko) 2012-09-04
JP2006503983A (ja) 2006-02-02
CN1705533A (zh) 2005-12-07
EP1554071A1 (fr) 2005-07-20
KR20050059285A (ko) 2005-06-17
CN1705533B (zh) 2010-08-11
ATE490830T1 (de) 2010-12-15
SE0203134D0 (sv) 2002-10-22
RU2005115474A (ru) 2005-10-27
TW201127521A (en) 2011-08-16
JP2010189769A (ja) 2010-09-02
DE60335280D1 (de) 2011-01-20
MXPA05004256A (es) 2005-07-05
PL375094A1 (en) 2005-11-14
CA2495697A1 (fr) 2004-05-06
AU2003269786A1 (en) 2004-05-13
BR0314079A (pt) 2005-07-05
PL208668B1 (pl) 2011-05-31
TWI415698B (zh) 2013-11-21
RU2333075C2 (ru) 2008-09-10
TW200417433A (en) 2004-09-16
WO2004037468A1 (fr) 2004-05-06
BR0314079B1 (pt) 2011-10-04
ZA200501296B (en) 2006-10-25
AU2003269786B2 (en) 2007-12-13
CA2495697C (fr) 2011-12-13
KR20110114689A (ko) 2011-10-19

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