US20050274222A1 - Method for making sintered body with metal powder and sintered body prepared therefrom - Google Patents

Method for making sintered body with metal powder and sintered body prepared therefrom Download PDF

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Publication number
US20050274222A1
US20050274222A1 US10/907,155 US90715505A US2005274222A1 US 20050274222 A1 US20050274222 A1 US 20050274222A1 US 90715505 A US90715505 A US 90715505A US 2005274222 A1 US2005274222 A1 US 2005274222A1
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Prior art keywords
sintered body
powders
recited
sintering
binders
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Abandoned
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US10/907,155
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English (en)
Inventor
Kuen-Shyang Hwang
Yung-Chung Lu
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TAIWAN POWDER TECHNOLOGIES Co Ltd
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TAIWAN POWDER TECHNOLOGIES Co Ltd
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Assigned to TAIWAN POWDER TECHNOLOGIES CO., LTD. reassignment TAIWAN POWDER TECHNOLOGIES CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HWANG, KUEN-SHYANG, LU, YUNG-CHUNG
Publication of US20050274222A1 publication Critical patent/US20050274222A1/en
Priority to US11/308,824 priority Critical patent/US20060201280A1/en
Priority to US12/366,627 priority patent/US20090142220A1/en
Priority to US12/366,624 priority patent/US20090142219A1/en
Abandoned legal-status Critical Current

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    • 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
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • 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
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1028—Controlled cooling
    • 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
    • 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
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • 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 generally relates to a sintered body and fabrication method thereof. More particularly, the present invention relates to compositions of sinter-hardening powders, the sintered body by using fine powders as raw materials, and the fabrication method thereof.
  • the design of the alloy of powder metallurgy is always the critical starting point for the development of powder metallurgy.
  • various alloy steels can be developed and applicable to diversified circumstances.
  • powder metallurgy components are required to possess mechanical properties suitable for their application fields.
  • hardening thermal processes like quenching followed by tempering are normally applied to the sintered components in order to obtain the desirable mechanical properties.
  • sinter-hardening powders have been developed, by adding high hardenability alloying elements such as molybdenum (Mo), nickel (Ni), manganese (Mn) or chromium (Cr) to iron powders, then pressing out the green compact through the conventional compacting process and then sintering the green compact, with the hardness above HRC30.
  • alloys produced by this method are Ancorsteel 737SH (Fe-0.42MN-1.40Ni-1.25Mo—C) from Hoegananes Corp.
  • the claimed powders are compacted by the conventional pressing process, sintered between 1130-1230° C., and then cooled at rates of 5-20° C./minute in order to reach the desired sinter-hardening effects.
  • This has improved the process by lowering the minimum cooling rate of 30° C./min, as described in the previously mentioned processes.
  • the mechanical properties, in particular, the ductility are still unsatisfactory.
  • fine powders are commonly used in the metal injection molding process.
  • the powders used in the traditional powder metallurgy process e.g. press-and-sinter process
  • the particle size of the powders used in metal injection molding is usually less than 30 ⁇ m, while the particles used in the press-and-sinter process are under 150 ⁇ m in size. Since the diffusion distances in fine powers are shorter, the added alloying elements can be homogenized more easily in the matrix materials. Therefore, components sintered from the fine powders possess mechanical properties better than those of the traditional press-and-sintered components.
  • the alloys commonly used for metal powder injection molding are the Fe—Ni—Mo—C alloy series, exemplified by MIM-4605 (1.5-2.5Ni, 0.2-0.5% Mo, 0.4-0.6% C, ⁇ 1.0% Si, the remaining portion is Fe), which has the best mechanical properties according to the MPIF standards.
  • This alloy after sintering, reaches a tensile strength of 415 MPa, a hardness of HRB62, and a ductility of 15%.
  • the sintered product has to be heat-treated (quenched and tempered). It then reaches a tensile strength of 1655 MPa, a hardness of HRC48, and a ductility of 2.0%.
  • the present invention is directed to a metal powder sintered body, by using a new composition and by using fine powers as the raw material.
  • the particle size of the powders is between 0.1 ⁇ 30 ⁇ m.
  • the sintered body fabricated has a high hardenability and the sintered body can attain excellent mechanical properties under the normal cooling rate (3-30° C./minute) inside the traditional sintering furnace.
  • a metal injection molding fabrication method is provided, by using the new compositions of the sinter-hardening metal powders in the conventional metal injection molding process.
  • the sintered compact can be treated with low temperature tempering, without quenching, to obtain excellent mechanical properties.
  • a powder metallurgy fabrication method is provided by using the new compositions of the sinter-hardening metal powders in conventional powder metallurgy processes (press-and-sinter process).
  • the sintered compact can be treated with low temperature tempering, without quenching, to obtain excellent mechanical properties.
  • a metal powder sintered body is provided, by using fine powders as the raw material with the sintered body containing the characteristic composition including iron (Fe), carbon (C), nickel (Ni), and at least one other strengthening element, in the ratios as follows: Ni: 3.0-12.0%, carbon: 0.1-0.8%, the strengthening elements: 0.5-7.0%, and the remaining portion is Fe.
  • the above-mentioned strengthening elements can be selected from the group consisting of Molybdenum (Mo), Chromium (Cr), Copper (Cu), Titanium (Ti), Aluminum (Al), Manganese (Mn), Silicon (Si), and Phosphorous (P).
  • the element carbon mentioned above can be provided by adding graphite or using carbon-containing carbonyl iron powders.
  • the sintered body of the above-mentioned powders has a tensile strength of over 1450 MPa, a hardness of over HRC38, and a ductility of over 1% without the use of any quenching process.
  • a metal injection molding fabrication method is provided.
  • the above-mentioned compositions of the sinter-hardening metal powders can be applied to metal injection molding.
  • the method comprises providing the powders and binders, while the diameters of elemental or alloyed powders are 0.1 ⁇ 30 ⁇ m.
  • the above-mentioned powders and binders are homogenously kneaded to form a feedstock.
  • the green compacts are then molded from the feedstock using the injection molding machine.
  • the binders in the above-mentioned green compacts are removed using the well-known solvent or thermal debinding methods.
  • the debound body is sintered and cooled at a cooling rate of 3-30° C./minute in the sintering furnace, which can be a regular furnace, such as a vacuum furnace or a continuous pusher furnace.
  • the process after sintering is the low temperature tempering process with the tempering temperature ranging from 150-400° C. and the time ranging from 0.5-5 hours, to improve the mechanical properties of the sintered body.
  • a powder metallurgy method using the above-mentioned compositions of the sinter-hardening metal powders into powder metallurgy processes (press-and-sinter process) is provided.
  • the method comprises providing the powders and binders, whereas elemental powders or alloying powders have diameters ranging from 0.1 ⁇ 30 ⁇ m.
  • the powder granulation process is performed to allow the powders and binders to bind into round granules. Thereafter, the above round granules are sieved in order to select appropriate particles with good flowability for the compacting machine.
  • the green compact is obtained by filling the particles into the die cavity, and this is followed by compacting the particles under high pressures.
  • the binder in the above mentioned green compact is removed during the debinding process.
  • the body is sintered in the sintering furnace, which can be a common furnace, such as a vacuum furnace or a continuous pusher furnace.
  • the cooling rate can range from 3-30° C./minute.
  • the post-sintering process is the low temperature tempering process with the temperature ranging from 150-400° C. and the time ranging from 0.5-5 hours to improve the mechanical properties of the sintered body. It is noted that the granulated powders in combination with the sinter-hardening alloy ingredients from the present invention and with the press-and-sinter processes can obtain components with excellent mechanical properties without the quenching process.
  • the present invention provides a formulation for the fine sinter-hardening type powders, applicable to the metal injection molding process or traditional powder metallurgy process (press-and-sinter process) so as to produce the sintered body (work piece) of high strength, high density, high hardness, and high ductility, with a lower production cost.
  • FIG. 1 is a cross-sectional view of the sample in example 1, observing the ductile microstructure with dimple type fractures by the scanning electronic microscope.
  • Table 1 and Table 2 The element ingredients and the mechanical properties of the sintered body are listed in Table 1 and Table 2, whereas examples 1-4 in Table 2 are the sintered bodies made from the metal injection molding process; examples 5-6 are the sintered body made from the traditional powder metallurgy process. Table 1 and Table 2 are used to illustrate the sintered body elements and the fabrication method for the present invention, while examples 1-6 represent the present invention and examples A-D are used as the comparison group according to the available literatures.
  • the elements of MIM-4605 used in injection molding are shown in Table 1, while the mechanical properties of the sintered body produced by the elements of MIM-4605 are shown in Table 2.
  • the elements of MIM-2700 used in injection molding are shown in Table 1, while the mechanical properties of the sintered body produced by the elements of MIM-2700 are shown in Table 2.
  • the elements of sinter-hardening alloy FLNC-4408 used in the traditional press-and-sinter process are shown in Table 1, while the mechanical properties of the sintered body produced by the elements of FLNC-4408 are shown in Table 2.
  • the required powders with particle sizes ranging from 0.1 ⁇ 30 ⁇ m are mixed together with 7 wt % of the binder, mixed in the Z type high shear rate mixer at 150° C. for 1 hour, then cooled to room temperature to obtain the granulated feedstock. Thereafter, the previously mentioned granulated feedstock is filled into the injection molding machine to produce the tensile test bar (e.g. the standard tensile bar from the MPIF-50 standard.).
  • the tensile bar is de-bound under the procedure applied from the known arts in the industry, for example, debinding for five hours using heptane as the solvent at 50° C., then heating the tensile bar in the vacuum furnace from the room temperature up to 650° C.
  • FIG. 1 is a fracture surface of the sample in example 1.
  • the ductile microstructure with dimple type fractures is observed using a scanning electronic microscope.
  • MIM-4605 Take the as-sintered MIM-4605 as an example, which is an injection molding material with the best mechanical properties listed by the MPIF. The properties are 415 MPa, HRB62, and 15% ductility, as shown in example A in Table 2. After quenching and tempering, the improved MIM-4605 will possess 1655 MPa, HRC48, and a ductility of 2%, as shown in example B in Table 2. MIM-4605 needs to be quenched and tempered to reach the mechanical properties similar to those made by the present invention. However, the sintered body of the present invention possesses good mechanical properties without the need for quenching.
  • the tensile bar has a tensile strength of 1780 MPa, a hardness of HRC-45, and a ductility of 4%.
  • the tensile bar has a tensile strength of 1720 MPa, a hardness of HRC-46, and a ductility of 4%.
  • the tensile bar has a tensile strength of 1450 MPa, a hardness of HRC-28, and a ductility of 4%.
  • the powders having particle sizes ranging from 0.1 ⁇ 30 ⁇ m and the required components are mixed together with 1.5 wt % of the binders.
  • the powders, water, and binders e.g.: Polyvinyl alcohol
  • the slurry is then atomized from the nozzle at high speed and dried by hot air or hot nitrogen to evaporate the water within.
  • the fine powders are thus bonded with each other by the binder to form granulated powders with good flowability.
  • the particle size of the graduated powder is about 40 ⁇ m.
  • the previously mentioned granulated powders are filled into the die cavity to produce the green tensile bar by the automatic compacting machine.
  • the tensile bar is de-bound under the procedure applied from the known arts in the industry. For example, the temperature will be raised at the rate of 5° C./minute up to 400° C., and then at the rate of 3° C./minute up to 1100° C., maintained for one hour, and then raised at the rate of 10° C./minute up to 1200° C., and sintering will continue at this temperature for one hour. Afterwards, the tensile bar is cooled as the temperature of the furnace drops, and the tensile bar is tempered for 2 hours at 180° C. without the use of the quenching process.
  • the tensile bar has a tensile strength of 1690 MPa, a hardness of HRC47, and a ductility of 3%.
  • FLNC-4408 the best sinter-hardened press-and-sinter work piece listed by the MPIF
  • FLNC-4408 has 970 MPa, HRC30, and 1% ductility, as shown in example D in Table 2.
  • the process is the same as in example 5, but with the compositions as shown in example 6 in Table 1. After 2 hours of tempering at 180° C., the tensile bar possesses a tensile strength of 1650 MPA, a hardness of HRC43, and a ductility of 4%.
  • the sinter-hardening alloy of the present invention can attain similar or even better mechanical properties without the quench-hardening process.
  • the problems derived from quench-hardening in the prior art including deformation, inconsistency of the dimensions, and cracking after quenching, etc, can be avoided in the present invention, and the costs from the quench-hardening process can be eliminated.
  • the sintered body of the present invention provides excellent mechanical properties, and it also provides advantages in the areas of dimensional control and lower costs.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
US10/907,155 2004-06-10 2005-03-23 Method for making sintered body with metal powder and sintered body prepared therefrom Abandoned US20050274222A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US11/308,824 US20060201280A1 (en) 2004-06-10 2006-05-11 Sinter-hardening powder and their sintered compacts
US12/366,627 US20090142220A1 (en) 2004-06-10 2009-02-05 Sinter-hardening powder and their sintered compacts
US12/366,624 US20090142219A1 (en) 2004-06-10 2009-02-05 Sinter-hardening powder and their sintered compacts

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TW93116634 2004-06-10
TW93116634 2004-06-10
TW93126297 2004-09-01
TW093126297A TWI246947B (en) 2004-06-10 2004-09-01 Method for making sintered body of metal powder and sintered body prepared therefrom

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US20070277497A1 (en) * 2004-02-04 2007-12-06 Sauren Gmbh & Co. Kr Fiber Guide Channel For An Open End Spinning Device And A Method For Producing A Fiber Guide Channel
US20120107170A1 (en) * 2010-11-03 2012-05-03 Kuen-Shyang Hwang Alloy steel powder and their sintered body
CN102672176A (zh) * 2012-05-23 2012-09-19 海安县鹰球集团有限公司 挖掘机用高耐磨粉末冶金球铰及其制造方法
TWI415956B (zh) * 2010-10-01 2013-11-21 Taiwan Powder Technologies Co Ltd 具有一大燒結窗的含鈦合金鋼金屬粉末及其燒結體
US20140037489A1 (en) * 2012-07-31 2014-02-06 Taiwan Powder Technologies Co., Ltd. Method of Producing Workpiece and Workpiece Thereof
CN103753844A (zh) * 2013-12-21 2014-04-30 湖北鄂信钻石材料有限责任公司 一种超细碳素生坯的真空压制方法
JP2015014041A (ja) * 2013-07-08 2015-01-22 住友電工焼結合金株式会社 シンターハードニング方法
US9095905B2 (en) 2012-10-15 2015-08-04 Hyundai Motor Company Method of manufacturing control finger using metal powder injection molding
KR101568383B1 (ko) * 2013-07-08 2015-11-12 영남대학교 산학협력단 금속분말 사출성형용 고강도 합금의 제조방법
CN105149589A (zh) * 2015-10-16 2015-12-16 中山耀威粉末元件有限公司 金属粉末冶金工件的注塑成型工艺
CN105618759A (zh) * 2016-01-29 2016-06-01 柳州市安龙机械设备有限公司 硬质合金刀片的烧结方法
WO2018034551A1 (ko) * 2016-08-19 2018-02-22 영남대학교산학협력단 금속 복합체의 제조방법 및 이에 의해 제조된 금속 복합체
CN109989865A (zh) * 2017-12-06 2019-07-09 斯凯孚公司 尤其用于燃料喷射泵的凸轮从动辊设备
US10457996B2 (en) 2016-03-23 2019-10-29 Rolls-Royce Plc Nanocrystalline bainitic steels, shafts, gas turbine engines, and methods of manufacturing nanocrystalline bainitic steels
CN112222410A (zh) * 2020-09-25 2021-01-15 重庆市巨力冶金制品有限公司 一种基于粉末冶金压制成型的油泵主动齿轮的制备工艺
US11137021B2 (en) 2018-06-06 2021-10-05 Aktiebolaget Skf Rolling bearing ring by metal injection molding process

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CN102655128A (zh) * 2011-03-03 2012-09-05 硕恩科技股份有限公司 多孔性石墨散热器及多孔性石墨的制备方法
CN103008662B (zh) * 2011-09-23 2015-06-03 复盛应用科技股份有限公司 复合金属的一体成型方法
TWI570245B (zh) * 2015-11-19 2017-02-11 Taiwan Powder Technologies Co Ltd A method for preparing a porous spherical iron-based alloy powder by a reduction reaction, wherein the powder and the powder are prepared Sintered body

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Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070277497A1 (en) * 2004-02-04 2007-12-06 Sauren Gmbh & Co. Kr Fiber Guide Channel For An Open End Spinning Device And A Method For Producing A Fiber Guide Channel
TWI415956B (zh) * 2010-10-01 2013-11-21 Taiwan Powder Technologies Co Ltd 具有一大燒結窗的含鈦合金鋼金屬粉末及其燒結體
US20120107170A1 (en) * 2010-11-03 2012-05-03 Kuen-Shyang Hwang Alloy steel powder and their sintered body
CN102672176A (zh) * 2012-05-23 2012-09-19 海安县鹰球集团有限公司 挖掘机用高耐磨粉末冶金球铰及其制造方法
US9962765B2 (en) * 2012-07-31 2018-05-08 Taiwan Powder Technologies Co., Ltd. Method of producing workpiece and workpiece thereof
US20140037489A1 (en) * 2012-07-31 2014-02-06 Taiwan Powder Technologies Co., Ltd. Method of Producing Workpiece and Workpiece Thereof
US9095905B2 (en) 2012-10-15 2015-08-04 Hyundai Motor Company Method of manufacturing control finger using metal powder injection molding
JP2015014041A (ja) * 2013-07-08 2015-01-22 住友電工焼結合金株式会社 シンターハードニング方法
KR101568383B1 (ko) * 2013-07-08 2015-11-12 영남대학교 산학협력단 금속분말 사출성형용 고강도 합금의 제조방법
CN103753844A (zh) * 2013-12-21 2014-04-30 湖北鄂信钻石材料有限责任公司 一种超细碳素生坯的真空压制方法
CN105149589A (zh) * 2015-10-16 2015-12-16 中山耀威粉末元件有限公司 金属粉末冶金工件的注塑成型工艺
CN105618759A (zh) * 2016-01-29 2016-06-01 柳州市安龙机械设备有限公司 硬质合金刀片的烧结方法
US10457996B2 (en) 2016-03-23 2019-10-29 Rolls-Royce Plc Nanocrystalline bainitic steels, shafts, gas turbine engines, and methods of manufacturing nanocrystalline bainitic steels
WO2018034551A1 (ko) * 2016-08-19 2018-02-22 영남대학교산학협력단 금속 복합체의 제조방법 및 이에 의해 제조된 금속 복합체
CN109989865A (zh) * 2017-12-06 2019-07-09 斯凯孚公司 尤其用于燃料喷射泵的凸轮从动辊设备
US11137021B2 (en) 2018-06-06 2021-10-05 Aktiebolaget Skf Rolling bearing ring by metal injection molding process
CN112222410A (zh) * 2020-09-25 2021-01-15 重庆市巨力冶金制品有限公司 一种基于粉末冶金压制成型的油泵主动齿轮的制备工艺

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