Royal Metal Powders Increases Capacity Formulated to Your Exact Specifications

POWDER METALLURGY

VOL. 4 NO. VOL. WINTER 2015 REVIEW

ADVANCES IN PM ALUMINIUM TECHNOLOGIES FOR ENHANCING PM PROCESSING OF PM TITANIUM

Published by Inovar Communications Ltd ipmd.net PowderMetallurgyReview FALL2015.pdf 1 8/19/15 11:26 AM

Publisher & editorial offices Inovar Communications Ltd FACILITIES 2 The Rural Enterprise Centre POWDER Battlefield Enterprise Park Shrewsbury SY1 3FE PEOPLE PRODUCTS United Kingdom METALLURGY

Editor & Publishing Director Paul Whittaker REVIEW Tel: +44 (0)1743 454992 Email: [email protected]

IMAGINATION DRIVES Managing Director Nick Williams Tel: +44 (0)1743 454991 INNOVATION Email: [email protected] Consulting Editor THE FUTURE OF PM SOLUTIONS HAS ARRIVED! Dr David Whittaker Consultant, Wolverhampton, UK

The potential of powder metallurgy is only Production limited by one’s imagination… Hugo Ribeiro, Production Manager Lightweight materials for Tel: +44 (0)1743 454990 Hoeganaes Corporation, the world’s leader Email: [email protected] high volume applications in the production of metal powders, Accuracy of contents For design engineers searching for lightweight, energy has been the driving force behind Whilst every effort has been made to ensure the the growth in the Powder accuracy of the information in this publication, saving components, the choice of material is critical. Metallurgy industry for over the publisher accepts no responsibility for Aluminium, processed via the Powder Metallurgy route, errors or omissions or for any consequences combines low weight with excellent formability at an 65 years. Hoeganaes has fueled arising there from. Inovar Communications Ltd that growth with successive waves cannot be held responsible for views or claims affordable cost. The PM process allows high volume expressed by contributors or advertisers, which production of complex aluminium components for a wide of technology are not necessarily those of the publisher. which have range of applications. expanded the Reproduction, storage and usage Single photocopies of articles may be made News of further investment in this sector by GKN Sinter use of metal for personal use in accordance with national Metals highlights the potential growth expected in the use powders for a copyright laws. Permission of the publisher and payment of fees may be required for all other of aluminium. In this issue of Powder Metallurgy Review we wide variety of photocopying. outline the PM aluminium production process and provide applications. All rights reserved. Except as outlined above, a number of industrial case studies that demonstrate the Hoeganaes Corporation Innovation Center no part of this publication may be reproduced, significant advantages that using this material has to offer The World Class in Cinnaminson, NJ, USA. The site houses stored in a retrieval system, or transmitted the Research and Development facilities Engineers and for advanced engineered powders, such as in any form or by any means, electronic, (page 35). AncorTech™ PM products and AncorAM™ photocopying or otherwise, without prior Scientists at powders for Additive Manufacturing. permission of the publisher and copyright owner. Hoeganaes’ new Innovation Center Another lightweight material, with characteristics that develop the new products and Submitting news and articles could lead to ever more diverse applications, is titanium. processes that move the We welcome contributions from both industry Currently the high cost and difficulty in processing this and academia and are always interested to hear material limits its adoption, however much research in this state of the industry about company news, innovative applications for PM, technology developments, research and area continues and we report on a number of processing forward, spanning more. routes discussed at the PM Titanium 2015 conference Automotive applications Please contact Paul Whittaker, Editor recently held in Lüneburg, Germany (page 57). to Additive Manufacturing. Tel: +44 (0)1743 454992 Email: [email protected] Our AncorTech products The PM industry recently met in Reims, France, for the o er customers more ecient Subscriptions annual Euro PM2015 Congress. Organised by the EPMA the PM solutions with enhanced Powder Metallurgy Review is published on a event attracted some 750 participants and included a well quarterly basis. It is available as a free electronic supported exhibition. We report on a technical session that dynamic properties, higher densities, publication or as a paid print subscription. The and greater design freedom. annual subscription charge is £85.00 including focussed on technologies for enhancing the PM process shipping. With melting, atomizing and mixing facilities (page 45). in North America, Europe, and Asia, Hoeganaes Advertising opportunities Contact Jon Craxford, Advertising Director, to Paul Whittaker serves our customers across the globe with the discuss how we can help promote your products Editor, Powder Metallurgy Review most advanced PM solutions. and brand, both online and in print. Tel: +44 (0) 207 1939 749 Fax: +44 (0) 1743 469 909 Email: [email protected]

Design and production Inovar Communications Ltd. FOLLOW US ON SOCIAL MEDIA AT: MOBILE DEVICE APPS NOW AVAILABLE FOR DOWNLOAD ISSN 2050-9693 (Print edition) @HoeganaesCorp Cover image ISSN 2050-9707 (Online edition) PM aluminium camshaft © 2015 Inovar Communications Ltd. bearing caps (Courtesy GKN Sinter Metals)

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in this issue 57 PM Titanium 2015: Developments in the powder metallurgical processing of titanium 37 Powder Metallurgy aluminium PM Titanium 2015, the third in the international components offer lightweight solutions series of conferences specifically focussed on and high volume production the processing, consolidation and metallurgy Powder Metallurgy aluminium components of titanium, was held in Lüneburg, Germany, provide design engineers with a lightweight, from August 31 to September 3, 2015. Dr David energy saving option for a range of applications. Whittaker reports on selected material and The process can offer unique material processing developments presented at the properties along with the ability to produce high event. volumes of complex aluminium components. Dr.-Ing. Thomas Schubert and Dr.-Ing. Thomas 67 Japan’s auto industry drives advances in Weissgärber, of Germany’s Fraunhofer IFAM in Powder Metallurgy technology Dresden, describe the production process and The winners of the JPMA’s 2015 Powder provide a number of case studies to highlight the Metallurgy Awards showcase the continuing possibilities of aluminium PM. developments being made to further expand the range of applications for Powder Metallurgy. The 45 Euro PM2015: Technologies for enhancing winning components recognise innovations in the Powder Metallurgy process new materials, manufacturing processes and A series of papers presented at the Euro PM2015 component design in a number of important Congress, held in Reims, France, October 4-7, industries. 2015, looked at the development of a number of Worldwide design tools for improved control of conventional Global manufacturer of nodular and spherical aluminum powders, press and sinter Powder Metallurgy processes. pre-alloyed aluminum powders, and aluminum premixes for PM These papers were included in a technical regular features www.ampal-inc.com www.poudres-hermillon.com session specifically dedicated to presenting ‘Tools for Improving PM’. Dr David Whittaker 4 Industry news reports on the key developments in this area. In the Americas 72 Advertisers’ index Supplier of carbonyl iron and atomized stainless steel powders for the PM and MIM industries 72 Events guide

United States Metal Powders, Incorporated 408 U.S. Highway 202, Flemington, New Jersey 08822 USA Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 email: [email protected] © 2015 Inovar Communications Ltd Winter 2015 Powder Metallurgy Review 3

USM 2013 PM Review and PIMI.indd 2 16/01/2013 10:41:40 QMP_pub_1212473_Mise en page 1 2012-12-19 13:47 Page1

GKN Sinter Metals to Federal-Mogul Powertrain invest $19.8 million in PM opens new manufacturing aluminium plant facility in China

It has been reported that GKN Sinter Metals plans to Federal-Mogul Powertrain has announced the opening invest $19.8 million at its Conover facility in North Caro- of Federal-Mogul (Anqing) Powder Metallurgy Co., Ltd, a lina, USA. The company plans to create 55 new manufac- new joint venture manufacturing facility that will produce turing jobs in the next five years with the expansion of its valve seats and guides for China’s domestic engine state-of-the art Powder Metallurgy aluminium manufac- manufacturers. Federal-Mogul Powertrain will hold the turing plant. majority share in the new joint venture. “The expanded Conover facility will build on GKN’s “Federal-Mogul Powertrain develops and delivers aluminium and lightweight technology capabilities that innovative technologies that meet specific regulatory and deliver lightweight and more energy-efficient designs and market requirements, helping our customers to improve From Ore To Powder, products to our customers right from our plant in North fuel economy, reduce emissions and enhance vehicle Carolina,” stated Alan Taylor, Vice President of Aluminium performance,” stated Olaf Weidlich, General Manager, To Meet Your Requirements! Technologies for GKN Sinter Metals. Valve Seats and Guides, Federal-Mogul Powertrain. The GKN Sinter Metals plant makes camshaft caps and “China is one of our key markets and our expanded valve transmission ends that are used in General Motors Corp., seat and guide footprint here will further strengthen our Metal Powders Ford Motor Co. and Fiat Chrysler automobiles. capability to serve global customers, as well as regional www.qmp-powders.com “Unique GKN developed Powder Metal Aluminium Asian customers.” materials open up fascinating application opportunities “The Anqing joint venture facility will manufacture for multiple industries, not just automotive; this invest- a range of global-leading Federal-Mogul Powertrain ment ensures GKN and North Carolina lead in aluminium patented powder metal technologies,” added Steven Powder Metallurgy technology,” added Taylor. Krause, Director of Operations, East Asia. www.gknsintermetals.com www.federalmogul.com

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Johnson Electric Metaldyne expanding Bluffton facility completes The POWDERS that Metaldyne, LLC, headquartered past five years, and this expansion is acquisition in Plymouth, Michigan, USA, has indicative of our continued commit- of Stackpole announced that it is expanding its ment to the community,” stated Bluffton, Indiana, USA, plant to Thomas Amato, President and CEO, make the PRODUCTS International support several transmission related Metaldyne LLC, and Co-President, programmes through the supply Metaldyne Performance Group (MPG). From the global leader in P/M and MIM powders Johnson Electric Holdings Limited, of ready-to-assemble differential Each of the future programmes headquartered in Hong Kong, has assemblies and aluminium valve planned for the Bluffton facility announced it has completed the bodies. Construction is expected to involves internal components which acquisition of Stackpole International, be completed by March, 2016. will be supplied from other manu- headquartered in Ontario, Canada. The expansion is the first step facturing locations of Metaldyne Stackpole is a supplier of highly-engi- in a five year multi-million dollar and also MPG companies, further Take innovation to the next power with AMETEK, the neered components to the automotive capital investment plan to support expanding Metaldyne’s platform of leader in powder metallurgy since 1970. industry including engine and trans- the launch and production of new vertical integration, the company mission pumps and Powder Metal- programmes. “Our Bluffton opera- stated. Whether you’re producing components for automotive, lurgy components. The company has tion has grown significantly over the www.metaldyne.com nine manufacturing facilities located aerospace, medical, marine or lock hardware applications, in North America, Europe and Asia. AMETEK Motor Vehicle Series, P/M Stainless, MIM, Dr Patrick Wang, Johnson Elec- tric’s Chairman and Chief Executive, Ultra Stainless and Titanium powders can be custom stated, “The combination of Stack- Royal Metal Powders increases capacity formulated to your exact specifications. pole’s pumps and powder metal Royal Metal Powders, Inc., located induction furnace and auxiliary equip- expertise with Johnson Electric’s in Maryville, Tennessee, USA, has ment in the water atomising depart- electric motor capabilities and global Regardless of the volume and properties you require, announced Phase 1 completion of ment to increase capacity. resources provides us with a unique a $2 million expansion project. The Royal Metal Powders also AMETEK has the ideal solution. Using proprietary opportunity to design and deliver inte- company, a subsidiary of American announced it has been awarded an methods for manufacturing superfine metal powders grated motorised pump solutions for Chemet, completed a 16,000 ft2 ISO 14001 Environmental Manage- our customers. These innovative new and roll-compacted powder, there’s a formulation building expansion which will house ment System (EMS) certificate for the products will strengthen the Group’s new tin powder atomisation produc- environmental management system that’s right for you. position as a leading supplier to key tion and additional inventory control. as it pertains to the manufacture and engine and transmission applica- Phase 2 of the expansion will sale of non-ferrous metal powders. tions that contribute to improved fuel Our powder allows you to provide innovative products include installing a larger second www.chemet.com economy and reduced emissions.” that add value to your existing capabilities, help you Johnson Electric acquired Stack- develop new markets, and meet your customers’ pole from SI Investors, L.P., a limited unique needs. partnership majority owned by Crest- view Partners, in an all-cash transac- tion that valued Stackpole at C$800 Merger of NTN Powder Metal million on an enterprise value basis. Corporation and Nippon Kagaku Yakin “We are very excited to take this next step with Johnson Electric,” Japan’s NTN Corporation has developed high-strength sintered added Peter Ballantyne, President announced that its consolidated products with major improvements Innovative & Advanced Metallurgical Technology and CEO of Stackpole. “It allows subsidiaries NTN Powder Metal made to fatigue strength and density. for the continued advancement of Corporation and Nippon Kagaku Yakin Nippon Kagaku Yakin Co., Ltd. P.O. Box 427 • Route 519 our core product portfolio and the Co., Ltd. will be merged on December was originally established in Osaka Eighty Four, PA 15330 USA development of innovative new tech- 1, 2015, to form NTN Advanced Mate- in 1947. The company relocated its Tel: +1 724-250-5182 • Fax: +1 724-225-6622 nologies to meet the changing needs rials Corporation. head office to Kameyama City, Mie www.ametekmetals.com of our industry. It also offers our NTN Powder Metal Corporation Prefecture in 2012 having joined the employees additional benefits from was established in 1966 as Toyo NTN Group in 2011. The company becoming part of a larger manu- Bearing Powder Metal Co., Ltd. The is active in the manufacture and facturing group that brings global company is located in Kanie Town, sales of sintered alloy products and breadth and financial strength to Ama District, Aichi Prefecture, and magnetic material products required support our growth initiatives over the in 1989 Changed its name to NTN for medical devices and industrial long term.” Powder Metal Corporation. In recent machineries. www.johnsonelectric.com years, the company successfully www.ntn.co.jp

(hardmetals), PM parts, and PM Japanese PM companies maintain magnets, as well as W, Mo, heavy growth despite decline in automobile metal, thermal management materials, ceramics, diamond tools production and hardmetals produced at the fully owned A.L.M.T. subsidiary. Most of the major Japanese Powder cemented carbide (hardmetal) The Industrial Materials and Metallurgy producers have reported tools, structural PM parts and Others division saw half year sales steady growth in sales in the first bearings, high performance alloy barely increase compared with half of the 2015/2016 financial year products and superalloys, were same period in 2014 to Yen 157.2 (April to September 2015), despite reported to have increased by 14.2% billion ($1.275 billion). Hardmetals the continuing fall in automobile year-on-year to Yen 77.7 billion (cemented carbides) sales increased production in the country. According ($629.8 million). Operating profits slightly to Yen 45.7 ($370.6 million) to statistics from the Japan Auto- for this division rose by 8% to Yen for the six month period, and sales mobile Manufacturers Associa- 9 billion. This division has particu- of Powder Metallurgy products saw tion (JAMA), output of all vehicles larly benefited from robust sales no change at Yen 28.9 billion ($234.3 declined by 7.5% in the first 9 of cemented carbide products, million). Sales at A.L.M.T. declined months of 2015 to 6.925 million including the recent acquisition of a by nearly 10% to Yen 22.4 billion units, of which 5,830 million were 51% share-holding in Hitachi Metals ($181.6 million). SEI is forecasting passenger cars, down 7.1%. More Ltd’s cemented carbide business second half sales (October 1 to than 90% of Japan’s PM production which took effect on April 1, 2015. March 31, 2016) of Yen 187.7 billion goes to the automotive sector. MMC reported that the company had ($1.522 billion) for the Industrial established cemented carbide end Materials division due in the main Hitachi Chemicals Co Ltd mill production in North America in to increased sales of unspecified Hitachi Chemicals Co Ltd, which April this year and that, in addition ‘Other’ products in this division. includes the two main business to adding capacity for carbide insert www.global-sei.com segments of Functional Materials production in Spain in December and Advanced Components and 2014, it is also planning to start Fine Sinter Co Ltd Systems, reported group sales up production of carbide drills and end Fine Sinter Co Ltd, based in by 9.3% to Yen 275.6 billion ($2.235 mills in that country from March Kasugai, operates two business billion) for the half year ended 2016. MMC will also double end mill segments which include Powder September 20, 2015 with net income capacity and launch carbide drill Metallurgy products based on up by 23.6% to Yen 17.1 billion production in Indonesia in October structural PM parts and Metal ($137.8 million). The Advanced 2016. The company claims to have Injection Moulding (MIM); friction Components and Systems division, more than 10% share of the global materials (for railway applications) which includes structural PM parts cemented carbide market. and hydraulic equipment such as and PM bearings as well as vehicle www.mmc.co.jp motor pumps, solenoid valves, etc. batteries, printed circuit boards and Automotive PM products make up diagnostic instruments, reported a Sumitomo Electric Industries Ltd nearly 90% of sales and railroad 21.2% increase in sales to Yen 137.3 Sumitomo Electric Industries Ltd applications, hydraulic equipment billion ($1.113 billion). Segment (SEI) based in Itami, Osaka, Japan, and industrial machinery the profit was static at Yen 3.4 billion. reported group sales for the period remainder. Fine Sinter Ltd reported www.hitachi-chem.co.jp April to September 2015 of Yen a 3.8% increase in half year sales 1,439 billion ($11.669 billion), an for the period ending September Mitsubishi Materials Corp increase of 9.8% compared with the 30, 2015, to Yen 19.3 billion ($156.4 Mitsubishi Materials Corp (MMC) same period in the previous year. million), and a 185% jump in net saw consolidated net sales for the Group operating income was up by income to Yen 1.009 billion. six month period to September 30, 10.4% to Yen 52.890 billion ($429 The company operates six 2015, total Yen 709.5 billion ($5.75 million). The largest SEI division, production plants in Japan, China billion) – down 5.5% on the corre- Automotive, which specialises in and Indonesia and is involved in a sponding period in 2014. Operating wiring harnesses, reported half joint venture with another Japanese profit increased by 6.3% to Yen 36.2 year sales of Yen 765.5 billion ($6.2 PM producer, Tokyo Sintered Metals billion ($293.4 million). The decline billion), an increase of 7.5%. SEI’s Ltd, for producing PM parts in the in sales was attributed to the effect Industrial Materials and Others USA at American Fine Sinter in of lower copper and copper alloy division is the third largest after the Tiffin, Ohio prices. However, net sales of the Automotive and Environment and www.fine-sinter.com Advanced Materials and Tools Energy divisions and includes the division (AM&T), which includes production of cemented carbides

Mehlmann appointed CEO Kovohuty Metal Avure Changes to HC Starck Board

of PMG Holding Powders appoints Technologies HC Starck has announced a number division. Reiss will also take over of changes to its Executive Board. responsibility for the Surface PMG Holding GmbH, Füssen, has Dr Krehl as new Sales Director changes its As of October 1, 2015, the group with Technology & Ceramic Powders. announced that Ulrich Mehlmann CEO of PMG name to Quintus nearly 2,800 employees and fifteen The Advanced Ceramic Components has been appointed as the company’s Holding with Kovohuty Dolný Kubín s. r. o, production sites worldwide will be led division will be handed over to Dr CEO following the resignation of Dr immediate located in Dolny Kubin, Slovakia, Technologies by four Executive Board Members. Matthias Schmitz, CFO of the group. Michael Krehl. The company stated effect. Mehl- Ulrich Mehlmann has appointed Thorsten Kiehnbast Edmar Allitsch, previously Head Dr Andreas Meier continues to that Dr Krehl asked the supervisory mann has a has succeeded Dr as the company’s new Sales Avure Technologies AB, head- of the Tungsten Powders division, be responsible for the Tantalum/ board to accept his resignation from long track- Michael Krehl as Director for non-ferrous powders. quartered in Västerås, Sweden, will take over the sales organisation. Niobium Powders division and Dr his position as Chairman of the record in the CEO of PMG Kovohuty is one of the largest has changed its name to Quintus Dr Michael Reiss, Chief Technology Dmitry Shashkov remains head of the management board and CEO due to automotive metal powder producers in Europe Technologies AB. The US subsidiary, Officer of the group, will assume Fabricated Products division. different opinions on group strategy. supply industry and has worked with a total capacity of over based in Columbus, Ohio is already the lead of the Tungsten Powders www.hcstarck.com The Vermögensverwaltung Erben successfully for Delphi Inc., TRW 10,000 mt/ year. Kiehnbast began named Quintus Technologies, LLC. Dr Karl Goldschmidt, PMG’s parent Automotive Inc., Tenneco Inc. and his career in Powder Metallurgy Avure Technologies Inc. in the corporation, added that it is still very most recently for Neumayer Tekfor over 29 years ago at one of the US will continue to focus on High interested in Dr Krehl’s expertise and GmbH (now part of the Amtek Group), largest metal powder producers in Pressure Processing (HPP) food knowledge and has asked him to sign both internationally and in Germany. Germany. processing machines and Quintus on as an advisor. Dr Krehl’s career PMG also announced that Michael Kovohuty provides a range of Technologies in Sweden and the at the PMG group spans almost 20 Kroeker has been appointed CFO, atomised copper and copper alloys, US will continue to focus on high years. The company added that he replacing Juan Miguel Garcia. tin powder, special ferro alloys pressure metal working and mate- has advanced the global footprint Kroeker has held various positions as well as ferro silicon powders rial densification equipment for the of PMG, initiated the development at automotive suppliers and most in different shapes and particle manufacturing industry. of new products and focused PMG recently worked as CFO and deputy distribution. The product range “Quintus Technologies is the to become a customer oriented CEO at HIB Part Solutions, a leading also includes electrolytic copper undisputed leader within high pres- company with a high reputation in the supplier of interior components for powders of dendritic shape from sure technology. Stemming from the automotive industry. the automotive industry. low to high densities. Swedish electro technical company Ulrich Mehlmann, 57, will succeed www.pmgsinter.com www.kovohuty.com ABB, we have over sixty years of experience of developing, building and installing systems for customers within the automotive and aerospace sectors and general industry,” stated Jan Söderström, CEO of Quintus Technologies. The Quintus press was the world’s first high pressure press, a design that was used to manufacture synthetic diamonds and other products. “The name Quintus Technologies underlines that we continue to focus on industrial customers requiring systems for sheet metal forming PM Tooling System or systems for cold or hot isostatic pressing. The re-naming is a small The EROWA PM tooling system is the standard part of a substantial effort now launched to strengthen our offer interface of the press tools between the and our position on all markets, toolshop and the powder press machine. from Europe to the Americas and especially Asia. The strong history Its unrivalled resetting time also enables of the Quintus name will help us to you to produce small series proﬁ tably. release the full potential,” added Söderström. www.erowa.com www.quintustechnologies.com

Eisenmann and AP&C installs two Ruhstrat merge new atomisation to form new reactors

industrial furnaces Arcam AB has announced that its company metal powder subsidiary AP&C, based in Montreal, Canada, is Eisenmann SE has announced that building its fourth and fifth reactors, its business unit for process and adding significant capacity to its high temperature technology will titanium and nickel superalloy merge with Ruhstrat GmbH & Co. powder manufacturing operation. KG to create Eisenmann Thermal AP&C uses proprietary plasma Solutions GmbH & Co. KG. The new atomisation technology to produce SEM of Ti-6AL-4V powder from AP&C organisation will be headquartered highly spherical powders of reactive in Bovenden, Germany, although and high melting point materials in a position to supply aerospace and the Böblingen site will continue to such as titanium, nickel, zirconium, medical part manufacturers’ titanium operate. molybdenum, niobium, tantalum, powders in volumes needed today Eisenmann began a sales partner- tungsten and their alloys. Its powders and in the future. With a multiple ship with Ruhstrat GmbH several are suited to a range of processes reactor operation, AP&C can produce years before acquiring the company such as Additive Manufacturing, its standard products on dedicated in 2011. “This move will allow us to Metal Injection Moulding, Hot reactors and equipment, therefore collaborate more closely than ever, Isostatic Pressing and coating eliminating cross-contamination particularly in our industrial furnaces applications. risks,” stated Jacques Mallette, HeatHeat treatment treatment at up at to1250°C 1300°C (2282°F) (2370°F) business,” stated André Görnhardt, “With this new generation of President of AP&C. Managing Director of Eisenmann atomising technology, AP&C is now www.advancedpowders.com We offer the complete material and heating solution Thermal Solutions. “By pooling the expertise that our teams have gained in thermal process technology over the last few EPMA launches Powder Metallurgy decades, we will be better placed component awards to effectively meet growing demand • Advanced powder metallurgical FeCrAlMo su- for global solutions, and to address The European Powder Metallurgy and to promote the benefits of using per alloy for service in the temperature range the challenge of more complex Association (EPMA) has announced the powder metallurgy process,” 800 to 1300°C (1470 to 2370°F) processes,” added Görnhardt. the launch of its prestigious EPMA stated Joan Hallward, Awards The Ruhstrat and Eisenmann Powder Metallurgy Component Coordinator. “Over the years, the • Combines excellent resistance to oxidation and teams will undertake joint R&D Awards 2016. The competition is EPMA Awards have done much to hot corrosion with high creep resistance / form projects in the areas of lightweight open to EPMA members who can promote and stimulate the interest stability materials and carbon fibre, high- demonstrate major achievements in PM technology and we hope that Flanges performance metals, technical in the successful commercialisation all members will seriously consider • Outstanding resistance to sulphur and ceramics, powder chemicals, cata- or innovation of a product, taking submitting an entry in this World carburizing environments lysts and new materials. Moreover, into account cost savings, improved Congress year.” the teams will consolidate and quality and stimulation of further There will be four categories for • Unique combination of strength and corrosion expand their marketing and engi- usage of PM technology. the 2016 awards: resistance at extreme temperatures neering activities. The awards will be presented • Additive Manufacturing • Applicable for structural parts like nozzles, A range of electrical technologies during the World PM2016 Congress • Applicable for structural parts like nozzles, • Hot Isostatic Pressing flanges, furnace rollers and retorts in a wide under the brand name of Ruhstrat & Exhibition to be held in Hamburg, flanges, furnace rollers and retorts in a wide Retort will complement and enhance the Germany 9-13 October 2016. A • Metal Injection Moulding range of high temperature processes existing Eisenmann product port- short video on each winner will • PM Structural • More energy efficient in high-temperature folio. Eisenmann stated that the new be prepared by the EPMA and all (including Hard Materials and processes than conventional materials organisation will be well equipped entries will be displayed as part of Diamond Tool parts) processes than conventional materials to react to changing market condi- an Awards Showcase in the World All entries must submitted tions with greater speed and flex- PM2016 Exhibition. via the EPMA Powder Metallurgy ibility, whilst tailoring products and “The EPMA Powder Metallurgy Furnace rollers Component Awards 2016 website no Want to know more? Contact your local sales representative - Furnace rollers processes to continuously evolving Component Awards 2016 compe- later than May 6, 2016. Want to know more? Contact your local sales representative - customer needs. tition will provide an excellent www.epma.com/awards or visit www.kanthal.com www.eisenmann.com opportunity for companies both to www.ruhstrat.com demonstrate their achievements

MPIF’s founding Executive Director Kempton H Roll dies aged 92

Kempton H Roll, founding Executive different sectors of the metal powder Director of the Metal Powder Indus- producing and consuming industries. tries Federation (MPIF), trade asso- Roll was also executive director of ciation for the international metal APMI International, the professional powder producing and consuming society for Powder Metallurgy that he industries, died on November 4, 2015, helped found in 1959, and served as Kempton H Roll, founding Executive following a short illness. He was 92 publisher of the International Journal Director of the MPIF years old. of Powder Metallurgy. Well known in the national and He attended Carnegie Institute of Distinguished Service to Powder international metalworking commu- Technology and graduated from Yale Metallurgy Award. In 2007, to honour nities, Roll retired in 1988 after a University in 1945 with a degree in his lifetime accomplishments, MPIF 40 year career. He joined the Lead metallurgical engineering and served created the Kempton H Roll PM Industries Association in 1948 as in the Pacific during World War II as Lifetime Achievement Award which is Technical Director with responsi- a bomb disposal officer with the US presented every four years. He was bilities for the former Metal Powder Navy. He earned a master’s degree named a Fellow of ASM International Buying and selling Association (MPA), forerunner of from Brooklyn Polytechnic Institute in 1987 and was a Legion of Honour MPIF. He was named Executive in 1953. member of the Minerals, Metals and Director of the MPA in 1956 and In 1992 Roll received the MPIF’s Materials Society. helped found the MPIF in 1957 as the prestigious Powder Metallurgy www.mpif.org powder metal umbrella organisation representing Pioneer Award and in 1988 the and furnace scrap Bodycote increases Carpenter Technology reports first worldwide, since 1946. HIP capacity quarter results

Bodycote has announced further Carpenter Technology Corporation cost improvements and reduce expansion of its high pressure Hot has announced financial results for overhead costs in our Specialty Isostatic Pressing (HIP) capability the quarter ended September 30 Alloys Operations (SAO) segment as with the addition of a new mid- 2015, reporting net income of $8.9 operating margins were relatively range vessel to increase its volume million. This compares to a reported flat sequentially notwithstanding the capacity. The new system will serve net income of $13.5 million in the significantly lower volume. The cost customers globally from its eastern same quarter last year. Net sales for improvement initiatives are particu- USA location, adding to the compa- Q1 of fiscal year 2016 were $455.6 larly important in this environment ny’s extensive range of installed million, and net sales excluding of declining volumes and will better capacity across North America and surcharge were $385.1 million, a position us to capitalise on the oper- Europe. decrease of $55.0 million (or 12%) ating margin benefits from these cost The new HIP system will be from Q1 last year, on 19% lower structure changes as the volumes focused on high pressure develop- volume. return.” ments in aerospace and advanced Operating income was $24.8 “As expected, our Performance materials. The unit is capable of million, an increase of $2.7 million Engineered Products (PEP) segment 1403 Fourth St. • Kalamazoo MI USA • 49001 processing up to 2,000 bar (30,000 on the previous year’s first quarter. was impacted by the lower sequential Mailing: PO Box 2666 • Kalamazoo MI USA• 49003 psi) and temperatures up to 2,000°C. Operating income, excluding pension demand in the current quarter for Call toll-free, USA: 1-800-313-9672 Bodycote operates over 50 earnings, interest and deferrals and Aerospace titanium fastener mate- Outside USA/Canada: 1-269-342-0183 HIP vessels in multiple locations. restructuring charges and special rials and powder products for the Fax: 1-269-342-0185 Processing capability can accommo- items, was $32.6 million, an increase Industrial and Consumer end-use date components up to 2 m diameter of $8.1 million (+33%) from the first market. The operating income results by 3.5 m high, weighing 0.1 kg to over quarter of the prior year. of the Oil and Gas businesses in PEP Contact Robert Lando 30,000 kg. In addition to standard “Overall I am encouraged by were sequentially flat as we continue Email: [email protected] quality and environmental certifica- how the team has responded to the to manage cost structure and take tions, Bodycote’s HIP facilities hold industry challenges in the quarter,” appropriate actions as a result of the ASTM, NORSOK and Nadcap accredi- stated Tony Thene, Carpenter’s depressed activity in this end-use tations. President and Chief Executive Officer. market,” added Thene. www.bodycote.com “We continued to drive operating www.cartech.com aceironandmetal.com

Industrial Solutions Functional Chemicals AIMS appoints new Director of Kennametal announces Business Development and Insight changes to management team and relocation plans Advanced Interactive Materials in component manufacturing, which Sciences Ltd (AIMS), based in is why I’m so excited to be joining Kennametal Inc. has announced two changes to its Peterborough, UK, has announced AIMS,” stated Dr Khan. “Through its executive management team. As of October 1, 2015, that Dr Raja Khan has joined the patented Sagittite® range, AIMS is Peter Dragich will become Kennametal Vice President company as its new Director of carving out a reputation for providing and Executive Vice President of the Infrastructure Business Development and Insight. the highest quality, wear- and Dr Raja Khan has joined AIMS business segment and as of September 30, 2015, Greg Dr Khan, a leading expert in the corrosion-resistant solutions for as its new Director of Business Temple will become Vice President and Chief Supply world of advanced metals and Hot customers across the globe, ranging Development and Insight Chain Officer. Isostatic Pressing (HIP) techniques, from Food processing to Oil & Gas Dragich will take global responsibility for growth joined the company from The Welding and Aerospace industries.” knowledge and contacts across a of the company’s engineered products and surface Institute (TWI), Cambridge, where “Together with AIMS’ near-net breadth of manufacturing sectors technologies, serving customers in earthworks, energy he was Senior Project Manager. Dr shape capability, which unlike globally, Dr Khan will be pivotal to and process industries. He joined Kennametal in Khan will continue his position® as traditional cast and forge processes our future growth in terms of product October 2012 as Vice President Integrated Supply Chain Keystonevisiting scholar at the University ofPowdered enables components to be Metaldevelopment Company and sales.” and Logistics. Prior to Kennametal, Dragich was Vice Birmingham. manufactured without the need for AIMS was founded 17 years ago President, Global Field Operations, Climate, Controls, His key focus at AIMS will be to second stage machining, there is a by the company’s Technical Director and Security for United Technologies Corporation. He drive sales of the company’s Hot great opportunity for continued sales Geoffrey Archer. In 2012 the company also served in several manufacturing management Isostatic Pressing consolidated growth.” received inward investment from positions at Ford Motor Company and was a Sergeant components featuring its Sagittite® AIMS Managing Director Mark Alycidon Capital Ltd and has seen in the United States Marine Corps. In addition, he range using powdered metal Hodgkins added, “The appointment continued growth in markets across brings more than 25 years of experience in supply chain chemistry, together with near-net of someone of Dr Khan’s calibre and Europe, China, Australia and the USA. management and cross-functional collaboration. shaping methods. reputation in the Powder Metallurgy www.aimsltd.com Temple will lead the company’s global manufacturing “Powder Metallurgy and near net and near-net shaping world is a real operations, distribution centres and reconditioning shaping technologies are the future coup for AIMS. With his technical facilities, as well as supply chain management, supplier sourcing, advanced manufacturing engineering and environment, health and safety. He joins Kennametal Metal Powder Lubricants from Sensata Technologies where he served as Senior Vice President of Global Operations. He previously held global operations leadership positions with Ecolab Acrawax® C Lubricant Corporation, Avery Dennison Corporation and The Clorox Company and has served as an operating partner for the Setting the standard in the metal powder industry, private equity firm Apollo Global Management. Acrawax® C Lubricant is a clean-burning, metal free Raising the potential for powdered metal applications lubricant that does not generate metallic or corrosive Relocation of headquarters byproducts. Acrawax® C Lubricant is combustible, leaving Kennametal Inc. has also announced plans to relocate its no residue on sintered parts. world headquarters to an urban location as it repositions MPIF 2015 MPIF 2014 Driven by GRAND the company for growth in global markets, recruits new GRAND PRIZE talent and strengthens innovative partnerships with PRIZE innovative thinking, AWARD AWARD Acrawax® C Lubricant Offers: Keystone has a solid leading universities. The company has expanded its presence in Pittsburgh, reputation for bringing industry Pennsylvania, and will move its corporate leadership – Precise particle size control firsts to market. team to the US Steel Tower in downtown Pittsburgh, – Free flowing powder mixes while maintaining a substantial presence at its current – Low die wear and easy part removal from the die Join us in pioneering headquarters in Latrobe, Pennsylvania. – Reduced part distortion the next leap forward “An urban location puts Kennametal in closer – Variety of custom particle sizes for powdered metal proximity to major universities, public transportation and manufacturing. the airport, while presenting us with new opportunities to innovate, grow and recruit new talent,” stated Kennametal Chairman of the Board, Bill Newlin. “The company believes that with cooperation of Pittsburgh www.keystonepm.com city, county and state officials an agreement for a new Contact us to learn more: Keystone Powdered Metal Company | 251 State Street | St. Marys, PA 15857-1697 | Phone 814-781-1591 building in Pittsburgh is realistic.” E: [email protected] Email: [email protected] www.kennametal.com T: + 1 201 316 9200 www.lonza.com

MPIF elects new President

The Metal Powder Industries Federa- Corporation for 25 years, most tion (MPIF) has announced that recently as Senior Vice Presi- Patrick J McGeehan, Vice President dent, Operations and Technology. and General Manager of the specialty McGeehan most recently served metal products division, Ametek, Inc., as president of the Metal Powder Patrick J McGeehan, MPIF President was elected the 28th President of the Producers Association (MPPA) and (left), Dean Howard, President of the federation, succeeding Richard Pfing- a member of the MPIF Board of Metal Powder Producers Association stler of Atlas Pressed Metals, DuBois, Governors. (centre) and Thomas K Houck, Presi- Pennsylvania. McGeehan’s two-year Active in the PM industry for dent of the Metal Injection Molding term took effect at the conclusion many years, McGeehan received Association (right) of the federation’s annual meeting the MPIF Distinguished Service to recently held in Austin, Texas. Powder Metallurgy Award in 2011. member of the MPPA Board of Direc- Two of the MPIF’s six associa- He is also a member of the MPIF tors since 2009, Howard obtained his tions also installed new Presidents Awards Committee, served on the PMT Level I certification in 2004 prior during the annual meeting. Dean MPIF Technical Board, co-chaired to joining the APMI Board of Directors Howard, Vice President, Sales, North MPIF’s Roadmap Strategy Board and in 2007. He served as APMI president American Höganäs, Inc., was elected has been a member of APMI Inter- from 2010 to 2014. president of the Metal Powder national for over 30 years. McGeehan Houck’s interest in engineering Producers Association (MPPA). co-chaired the 1990 annual MPIF PM and PM began in 1987 while Thomas K Houck, Vice President, US conference in Pittsburgh, Pennsyl- serving in the US Army. He honed MIM operation, ARCMIM, was elected vania, as well as the 2008 PM World his management skills at Zenith president of the Metal Injection Congress in Orlando, Florida. Sintered Components, MascoTech/ Molding Association (MIMA). Howard has been promoting Metaldyne Sintered Components McGeehan’s PM career spans PM technology since entering the and Cloyes Gear & Products before over 30 years. He earned his BS and industry in 1991 as a Sales Manager entering the MIM industry. An active MS degrees in Materials Science & for Abbott Furnace Company. In 1997, member of MIMA, Houck co-chaired Engineering from Drexel University. he joined Pyron Corporation and the MIM2015 conference and will McGeehan has been with Ametek, was retained after its acquisition by co-chair the upcoming MIM2016 Inc., for seven years and, prior to North American Höganäs, where he conference. Ametek, Inc., he was at Hoeganaes is currently Vice President of Sales. A www.mpif.org

and are unrivalled in Alumina, we Alcoa to split business to form two have optimised Aluminium, flexed independent companies our energy assets and turned our casthouses into a commercial Alcoa’s Board of Directors has unani- proposition and operational and success story. The upstream business mously approved a plan to separate financial characteristics. After the is now built to win throughout the into two independent publicly-traded separation, the Upstream Company, cycle. Our multi-material value-add companies. The move will see the with its strong history in the business is a leader in attractive formation of an ‘Upstream Company’ aluminium and alumina markets, will growth markets. We have intensified and a ‘Value-Add Company’ and operate under the Alcoa name. The innovation, made successful is expected to be completed in the Value-Add Company will be named acquisitions, shed businesses without second half of 2016. prior to closing. “In the last few years, product differentiation, invested in The Upstream Company will we have successfully transformed smart organic growth, expanded our comprise five business units that Alcoa to create two strong value multi-materials profile and brought today make up Global Primary Prod- engines that are now ready to key technologies to market; all while ucts - Bauxite, Alumina, Aluminium, pursue their own distinctive strategic significantly increasing profitability,” Casting and Energy. The Value-Add directions,” stated Klaus Kleinfeld, added Kleinfeld. Company will include Global Rolled Chairman and Chief Executive Officer. Alcoa recently announced a $60 Products, Engineered Products and “After steering the Company million expansion of its R&D centre Solutions, and Transportation and through the deep downturn of to grow its Additive Manufacturing Construction Solutions. 2008, we immediately went to work business as well as a further $22 Alcoa stated that both independent reshaping the portfolio. We have million investment in HIP technology companies will attract an investor repositioned the upstream business; at its facility in Whitehall, Michigan. base best suited to their unique value we have an enviable bauxite position www.alcoa.com

Miniature rotary MIM2016 New 2016 edition Plansee wins batch mixer from Conference of PM Standard Schneider Electric Munson Machinery Programme Test Methods supplier award

Munson Machinery, Utica, USA, The MIM2016 International Confer- The MPIF has announced the publi- The two production sites of Plansee has announced the introduction of ence on the Injection Molding of cation of its 2016 edition of Standard BU Power T/D, located in Seon and a new miniature rotary batch mixer Metals, Ceramics & Carbides will Test Methods for Metal Powders and Shanghai, have been named as to its range. The model MX-1-SS is take place at the Hotel Irvine in Powder Metallurgy Products. The preferred suppliers to Schneider capable of blending up to 28 litres of The Miniature rotary batch mixer Irvine, California, USA, from March MPIF Standard Test Methods publica- Electric for the fifth time in a row. dry bulk ingredients, with or without from Munson blends batches up to 7-9 2016. The conference, spon- tion contains 42 standards covering Particle Size Using Air Permeability) Plansee manufactures switch contact liquid additions, in ratios down to one 28 ℓ,or 45 kg, of dry bulk ingredients, sored by the MPIF’s Metal Injection terminology and recommended and includes new Precision State- components from WCu and CuCr for part per million with total uniformity with or without liquid additions Molding Association (MIMA), has methods of test for metal powders, ments for five standards. Schneider Electric. in two to three minutes, regardless the objective of exploring the latest Powder Metallurgy and injection A new General Information VI “We are proud of our employees’ of disparities in the bulk densities, Also offered are large-scale, advances in the field of Powder moulded parts, metallic filters and section has been added to this edition performance in a difficult market particle sizes or flow characteristics in-line rotary batch mixers with Injection Moulding. PM equipment. that provides details (QR codes and environment. They were successful of batch ingredients, the company capacities of 142 litres to 17 m3, In addition to the conference The most current versions of these Internet links) on viewing educational to differentiate our offer in such a states. continuous rotary blenders, ribbon/ there will be an optional Powder standards, which are used in the video clip demonstrations of the competitive market environment,” The mixer is equally efficient down paddle/plow blenders, vee-cone Injection Moulding Tutorial taking manufacture of both metal powder working mechanics of a number of stated Frank Müller, Head of BU to five percent (1.4 litres) of rated blenders, high intensity blenders and place on March 7. Conducted by and Powder Metallurgy products, cited test methods. Power. capacity, making it suitable for accu- fluidised bed mixers. Size reduction Prof Randall German, San Diego are required by Quality Assurance Publication of the 2016 edition Plansee uses Powder Metallurgy rately determining outcomes when equipment produced by the company State University, the course is an programmes in order to maintain full of this standard renders the 2012 to produce the metallic composite scaled up to larger Rotary Batch includes screen classifying cutters, ideal way for anyone looking for a compliance. edition (and prior editions) obsolete materials in switch contacts. The Mixers. The company currently offers centrifugal impact mills, rotary lump solid grounding in PIM to obtain a The 2016 edition contains revisions and the MPIF states that previous process offers harmonized mate- six miniature rotary batch mixer breakers, attrition mills, hammer comprehensive foundation in a short to 27 standards, including major editions should be no longer distrib- rial properties and an exceptionally models in maximum batch capacities mills and shredders. period of time. rewrites of Standards 10 (PM Tensile uted and should be destroyed. homogeneous material composition. of 7 to 425 litres or 1 to 544 kg. www.munsonmachinery.com www.mpif.org Properties) and 32 (Estimating www.mpif.org www.plansee.com

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GKN Sinter Metals receives Johnson ASM Handbook on Controls Performance Award Powder Metallurgy

Powder Metallurgy parts maker The 2015 edition of ASM Handbook, GKN Sinter Metals’ facility in Bonn, Volume 7: Powder Metallurgy, Germany, has received a Silver edited by Prasan K Samal and Performance Award 2015 from Joseph W Newkirk, is now available Johnson Controls (JCI), one of the from the publishers. The latest world’s largest automotive suppliers. 907 page edition focuses on The award was for supplying PM conventional press and sinter components used in the manufacture Powder Metallurgy (PM) and Keiper awards from 2006 to 2010 The flair and flexibility you need of car seats. includes a new section on Metal Timothy Laughlin, RPPC Engi- Silver Performance Award in 2011. Injection Moulding (MIM). neering Director and Thomas Since 2000, GKN Sinter Metals The revised volume is organised Jeworrek, Key Account Manager, Bonn has supplied Keiper with in two parts. The first part, following accepted the award during the Global metal wedges that enable seats to an introductory division on history Automotive Seating Supplier Awards recline. By 2014 GKN Sinter Metals and material standards, covers the and Expectations Day on GKN Sinter had produced one billion wedges at basic principles and techniques that Metals’ behalf. The award is presented Bonn, all made without any defects. are common to all PM materials. to suppliers who excel in key busi- Matthias Voss, Plant Manager of the The second part of the handbook ness areas such as quality, logistics, Bonn plant, stated, “We are delighted covers detailed information on PM technology and service. JCI is one of to receive this award from our technology as it applies to individual GKN Sinter Metals’ top ten customers valued customer Johnson Controls. metal/alloy families. Within each in Bonn. The plant has shared a It validates all the hard work by material-specific division, the long-term customer relationship with our employees to produce quality information presented follows Keiper, which became a subsidiary of products and our commitment to our the typical production steps and JCI in 2011, having already received customers to be partners in creating processes as they are currently Keiper Supplier Award in 2006, 2008, innovative solutions.” used in industry. 2009 and 2010. It also received a JCI www.gknsintermetals.com www.asminternational.org

The Press for Every Requirement! Productive. Energy-saving. Reliable. Mechanical-Hydraulic A Global Supplier Of Non-Ferrous Powder Compacting Press KPP Products Include: Pressing force 2500 – 4500 kN Metal Powders with a reputation for • Upper ram, mechanically driven for low energy consumption • Die and additional axes, hydraulically driven • Copper • Positioning accuracy within 0,01 mm - Irregular • Highest productivity for complex as well as simple structural parts • QUALITY - Spherical • FLEXIBILITY - Iron powder • Higher Yield - Dendritic - Press KPP 2500 • CUSTOMER SERVICE • Faster ROI • Copper Alloys - 15 strokes / min • NEW PRODUCT - Ø 82 mm • Tin DEVELOPMENT • Press-ready premix bronzes Makin Metal Powders (UK ) Ltd has achieved its current position • Infiltrants We will be glad to inform you in more detail about this technology! as one of the leading Copper and Copper Alloy powder producers • Speciality powders in Europe by supplying the powders that match customer

OSTERWALDER AG OSTERWALDER Inc. OSTERWALDER (Shanghai) technical specifications in the most cost effective manner on a 3250 Lyss Jim Thorpe, PA 18229 Technology Co., Ltd., Shanghai 201702 Switzerland USA P.R. China consistent basis, batch after batch. Phone +41 32 387 14 00 Phone +1 570 325 25 00 Phone +86 21 69 79 50 66 www.osterwalder.com Makin Metal Powders (UK) Ltd

Howards Racing Components offers 3D Printing with Binder Jetting Technology high performance powder forged connecting rods to aftermarket

Howards Racing Components, “It uses task-oriented steel mate- based in Oshkosh, Wisconsin, USA, rials that are too costly for high is offering a range of powder forged performance OEM connecting rods. Powder Metallurgy connecting rods Howards tailored the composition to to the performance aftermarket excel in a racing environment when The hot forging process uses a sector. As reported by enginelabs. developing these products.” 750 ton press to ensure the material’s com, the connecting rods are Powder forging can offer signifi- dense structure is finalised prior to produced in partnership with GKN cant advantages in the produc- the machining operations (Image Sinter Metals and together the tion of connecting rods. It offers courtesy enginelabs.com) companies have developed a product higher material utilisation over that is aimed at performance engine drop forged alternatives, as well as models from billet. We also use Finite builds. better weight variation control. The Element Analysis to accurately simu- “Forged powder metal technology process involves a reduced number of late stress and reaction to stress, features an extremely dense grain machining operations and has lower which allows for better strength structure when compared to a billet overall production costs. and weight reduction in the correct or conventional forging,” stated “We used CAD solids modelling places,” added Mugerauer. HRC’s President, Steve Mugerauer. for proof of concept and machined www.howardscams.com

YaHao Materials Molycorp to Atomisation for & Technology end rare earth metal powders aims to be China’s production at short course leading alloy Mountain Pass returns

powder supplier Molycorp, Inc. has announced that it Atomising Systems Ltd and Perdac

will end production of rare earths at Ltd (now part of CPFResearch Ltd) ® YaHao Materials & Technology Co,. its Mountain Pass facility in Calil- have announced that their popular ExOne Systems & Services offer durable 3D printed metal parts with Ltd., based in Hebei Province, China, fornia, USA, by October 20, 2015. two day intensive course, Atomisa- is one of the region’s largest manufac- The move follows the company’s tion for Metal Powders, is scheduled limitless complexity for prototype and series production volumes. turers of soft magnetic powders. The statement in June this year that it to take place in Manchester, UK, company is now offering a wide range had filed for Chapter 11 bankruptcy February 25-26, 2016. • No tooling required • True design freedom • Broad material applications of other alloy powders for various protection to restructure $1.7 billion The course, now in its 12th year, applications and is aiming to be the of debt. will consist of presentations from leading alloy powder supplier in China. Molycorp stated that it will Andrew Yule (Emeritus Professor Sales in 2014 were reported to be transition its Mountain Pass rare Manchester University), John Dunkley Select from a variety of build sizes: around 10.1 million RMB with exports earth facility to a ‘care and main- (Chairman, Atomising Systems accounting for around 50% of the tenance’ mode while it plans to Ltd) and Dirk Aderhold (Technical company’s total consolidated sales. continue serving its rare earth oxide Director, Atomising Systems Ltd). The company has more than 120 customers via its production facilities Sessions will cover the main employees and alloy powder produc- in Estonia and China. methods of atomising metals, the tion for the year totalled 2,365 tons. Rare earth pricing, which has specific requirements for different YaHao states that it has multiple declined dramatically over the past classes of metal, the design, opera- ™ ® ™ water and gas atomisation systems four years, was named as a key tion and economics of plant, meas- M-Print M-Flex Innovent with alloy powder capacity currently factor in the decision to suspend urement methods and an introduc- 800 x 500 x 400mm 400 x 250 x 250mm 160 x 65 x 65mm being around 5,000 tons per year. Its rare earth production at the site. tion to modelling and prediction range includes powders for Metal Customers of the company’s rare techniques. All current atomiser Injection Moulding, pre-alloyed earth magnetic materials, as well as types are covered together with a powder for diamond tools, amor- its rare earth-based water treatment wide range of metals and powder phous powder and single element products, will not be impacted, the types. powders. company stated. www.atomising.co.uk www.yahaochina.com www.molycorp.com www.cpfresearch.com

Researchers combine diamond and Porvair supplies sintered filters to cubic boron nitride with a novel alloying major South African refinery

process for a superhard material Porvair Filtration Group, UK, has fines - very small particles used in announced it has supplied highly the Fluid Catalytic Cracking process Researchers at Sichauan University, performance. efficient and durable sintered metal (FCC) of most large, modern oil refin- China, University of Nevada, USA, and The paper, Diamond-cBN alloy: A powder Triple Element Filters eries and in the hydrogen process the Chinese Academy of Sciences, universal cutting material, published (TEFs) to South Africa’s national stream at Mossel Bay. China, have published work on in Applied Physics Letters, reports oil company, PetroSA, through its The assemblies were selected by the combination of diamond and the synthesis and characterisation Johannesburg-based agents, Sagisa PetroSA for their ability to operate Triple Element Filter from Porvair cubic boron nitride to form a new of transparent bulk diamond-cBN Process Engineering (Pty) Ltd. reliably at temperatures in excess of superhard material suitable for alloy compacts whose diameters Bulk diamond-cBN alloy samples PetroSA, situated in Mossel Bay, is 400°C and at a pressure of around turing components for one of the cutting tool applications. (3 mm) are sufficiently large for synthesized at 20 GPa/2200 °C with the world’s third largest gas-to-liquid 25 bar. The vessels are located above world’s most environmentally friendly Diamond and cubic boron nitride them to be processed into cutting a diameter of ~3 mm, over a copper (GTL) facility and produces some the Catalyst Reduction Reactor oil companies. We believe that our (cBN) as conventional superhard tools. The testing results show screen to exhibit its transparency of the cleanest fuels on the market (CRR), enabling the TEF assemblies filtration expertise can help drive materials have found widespread that the diamond-cBN alloy has c and d: Polished rake faces of by using leading environmentally to be cleanable in situ, therefore further efficiency and cost reductions industrial applications, but both have superior chemical inertness over diamond-cBN alloy cutters (D. W. He/ friendly processes. operating in a cyclic back flush at the Mossel Bay refinery, in turn inherent limitations. Diamond is polycrystalline diamond and higher SCU) Porvair supplied 2.4 m long TEF operation to remove the catalyst cake providing sustainable growth,” stated not suitable for high-speed cutting hardness than single crystal assemblies, manufactured in the from the filter surface of the TEFs. Market Manager, Andrew Fairlie. of ferrous materials due to its poor cBN. High-speed cutting tests on granite. The alloy also demonstrated UK, as well as sintered metal mesh The disengaged catalyst then falls “PetroSA already produces some chemical inertness, while cBN is only hardened steel and granite suggest a more preferable high-speed fuse assemblies manufactured at into the CRR. of the cleanest fuels available and we about half as hard as diamond. that diamond-cBN alloy is indeed a cutting performance than either the company’s US factory. The TEFs As a consequence, the TEFs are are certain that the provision of our Because of their affinity in universal cutting material. polycrystalline CBN or commercial and mesh fuses were fitted into able to operate for a prolonged period TEF and mesh fuse assemblies, with structural lattices and covalent The researchers tested the polycrystalline diamonds. tubesheets and installed into five in an aggressive environment, only their high performance capabilities, bonding character, state the authors cutting performances of the alloy Future work for the team involves vessels, supplied locally by Sagisa. periodically requiring to be removed will only enhance that reputation by of the paper, diamond and cBN could on hardened steel and granite bars developing synthesis technology The complete vessels were then and chemically cleaned before then ensuring security and continuity of form alloys that can potentially fill on a CNC lathe. They found that for centimetre sized diamond-cBN shipped to the PetroSA refinery and being re-installed. supply.” the performance gap. However, the the diamond-cBN alloy rivalled alloy bulks to bring the process up to are now helping to clean up catalyst “Porvair is proud to be manufac- www.porvairfiltration.com idea has never been demonstrated polycrystalline cubic boron nitride’s industrial-scale production. because samples obtained in the wear and tool life on the steel http://apl.aip.org previous studies were too small samples and exhibited significantly to be tested for their practical less wear when cutting through Work Smarter... There’s no longer any need for skilled Dr. Fritsch delivers 1000 field-assisted operators to waste time on tricky and time- sintering presses consuming alignments.

Dr. Fritsch, a manufacturer of achieve very high densities and a very In other words, with System 3R’s reference field-assisted sintering systems homogeneous material structure. systems, production takes place in a more based in Fellbach, Germany, has The DSP-507 FAST sinter press sensible and more economical way. It’s simply announced the delivery of its 1000th delivered to Oxford University will a matter of working smarter. sinter press. The company stated help researchers develop innovative that Oxford University, UK, received Powder Metallurgy solutions for Setting–up times are minimised – One Minute Jens Huber (left) and Alasdair the new sinter press machine various applications. The university Morrison (right) with the 1000th FAST Set-up. which is capable of sintering a wide performs research for a number sinter press (type DSP-507) range of materials up to 2,400°C at of industrial customers. “It was a maximum pressure of 260 kN. It important for us to buy a machine features a fine vacuum level of 0,05 from a manufacturer which is also applications. A profound R&D work mbar and is equipped with many able to deliver turnkey production is very important for developing sensorial options, some customised equipment with this technology to such new applications and therefore or developed especially for the our industrial customers,” stated we are very happy that our 1000th university. Alasdair Morrison, Oxford University. machine goes to a high-class R&D The Field-Assisted Sintering “The applications for field-assisted facility like Oxford University,” stated Technique (FAST) systems from Dr. sintering are steadily increasing. Jens Huber, International Sales Reference systems Fritsch utilise Joul`s Heating and Examples are thermoelectric Manager, Dr. Fritsch business unit System 3R International AB, Sorterargatan 1, SE-162 50 VÄLLINGBY, tel +46-08 620 20 00, fax +46-08 759 52 34, achieve short sinter cycles. This, materials for generating energy out Powder Shaping Technologies. e-mail: [email protected], www.system3r.com states the company, allows it to of waste heat and nano-material www.fastsintering.com

Rosenhain Medal Kennametal awarded to recognised with Your partner for innovative manufacturing Banerjee Bosch Global

Dr Sarbajit Banerjee, an affiliated Supplier Award faculty member in the Department of Kennametal Inc. has announced that Materials Science and Engineering at it has been awarded the Bosch Global Texas A&M University, USA, has been Supplier Award 2015 from Robert awarded the Rosenhain Medal and Prof Dr Karl Nowak, President Bosch GmbH. The biannual award Prize by the Institute of Materials, Corporate Sector Purchasing and recognises outstanding performance Minerals, and Mining (IOM3), UK, for Logistics Robert Bosch GmbH, at the in the manufacture and supply of his research in new materials design. award ceremony of the ”Bosch Global products or services, notably in the The award was instituted in Supplier Award 2015” in Stuttgart areas of quality, costs, logistics and 1951 to honour the memory of the innovations.“It is an honour to be and total cost of ownership as well German-born Australian metallurgist recognised by Bosch as the only as guarantee global footprint and Walter Rosenhain. tooling manufacturer to receive their significant sales in the purchasing Banerjee, who is a professor in the Global Supplier Award,” stated Don category. Department of Chemistry at Texas Nolan, Kennametal President and “The Bosch Global Supplier Award A&M, received the honour in recogni- CEO. honours our top suppliers, who play tion of distinguished achievement in Kennametal was among 58 such a key role in Bosch’s success,” any branch of materials science by a suppliers out of 35,000 that Bosch added Dr Volkmar Denner, Chairman researcher under the age of 40. It is presented with the prestigious of the Bosch board of management. the highest young researcher award award. To be eligible, suppliers must www.kennametal.com presented by the organisation. deliver best-in-class services, quality The award recognises the accomplishments of Banerjee’s research group related to phase transformations in complex oxides, Powder Sintering Fundamentals II – new Metallurgy of light metals and the publication includes key papers ability to bring together theory, measurement and applications. on sintering Banerjee received his under- A new 274 page publication entitled The following paper by Austrian graduate education at St. Stephen’s Sintering Fundamentals II, edited scientists, H Danninger and C College, Delhi, India, and his by Professor Dr G S Upadhyaya, Gierl-Mayer covers the sintering doctorate at Stony Brook University, is now available from Trans Tech aspects of Cr- containing steels New York, USA. Before starting at Publications Inc. Following the in which dilatometry coupled with Texas A&M University he was an publication of the first volume in mass spectroscopy is shown as Assistant and Associate Professor 2009, the second volume contains a good tool for sintering process at the University at Buffalo and The Renishaw Solutions Centres provide a secure development environment seven papers written by respected control. This is then followed by a State University of New York. authors from five countries. joint paper from Russian scientist I in which you can build your knowledge and conﬁ dence using additive His research specialities include The first paper, authored by Konyashin with Austrian scientist manufacturing (AM) technology. solid-state and materials chemistry, Professor Upadhyaya (India), covers W Lenguer, which encompasses nanoscale materials, electronic historical aspects of sintering functionally graded cemented Equipped with the latest AM systems and staffed with knowledgeable engineers, Renishaw Solutions Centres offer you a fast structure, chemical imaging and fundamentals which began in the carbides. and accessible way to rapidly deploy this exciting technology in your business. X-ray spectroscopy, thin films and middle of the 20th century. The The next two papers deal with coatings, light metals and nanocom- Highlights include: coverage of literature is extensive, ceramic systems. ‘Doped Ceria posites. most of which is available only in the based Oxide Fuel Cell Electrolytes • Metal additive manufacturing for industrial applications www.engineering.tamu.edu print form. and their Sintering Aspects’, • Global network of Solutions Centres The second paper, authored by presents an exhaustive review R M German (USA), presents an (P Datta, India). Finally, in the • Applications expertise for a wide range of industries approach that links to the global last paper K Biswas and others • Integrated manufacturing solutions energy reduction during sintering. (India) discuss sintering and The third paper authored by M S microstructural modifications of Find out more at www.renishaw.com/additive Kovalchenko (Ukraine) is entitled seeded and neodymium doped ‘Rheology and Kinetics of Pressure lanthanum hexaaluminate. Sintering’. www.ttp.net Renishaw plc Brooms Road, Stone Business Park, Stone, Staffordshire, ST15 0SH, United Kingdom T +44 (0)1785 285000 F +44 (0)1785 285001 E [email protected] www.renishaw.com 28 Powder Metallurgy Review Winter 2015 © 2015 Inovar Communications Ltd

Fachmetall presents awards to Simplifying the recycling of permanent R. Biemmetech and X-Pore magnets

Fachmetall GmbH, Radevormwald, the support of Fachmetall and took The Fraunhofer Institute for Silicate The new recycling method utilises Germany, a metallurgical labora- appropriate action to improve the Research ISC, based in Alzenau, the melt spinning process, also tory specialising in Powder Metal- quality of its products. Ongoing Germany, has reported a new, known as rapid solidification, where lurgy and wrought materials, has efforts are being made to main- simplified process route for the researchers begin by melting the The researchers use a melt spinning announced the winners of its annual tain and continuously improve the Holger Davin of Fachmetall (left) and recycling of permanent magnets magnet. The liquefied material, process for the recycling of perma- industry wards. product quality. Dr Georg Schlieper (right) presenting that is claimed to enable the fast heated to more than 1000°C, is nent magnets (Image © Fraunhofer The Fachmetall QM Context For the first time, this year’s the Fachmetall QM Context Award and cost-effective recycling of the directed via a nozzle onto a water- Project Group IWKS) Award was presented to R. Biemme- Fachmetall PM Qualification Award to Massimiliano Rovinelli and his rare earth elements neodymium and cooled copper wheel that rotates at a tech srl, based in Fano, Italy, received was presented to a company with engineers dysprosium. speed of 10 to 35 metres per second. used to change the properties of the for outstanding efforts in enhancing a main focus outside the metals Currently, methods of recycling As soon as the melted droplet comes permanent magnet. In a further step, its quality management procedures. sector. X-Pore bv in Helmond, The permanent magnets involve into contact with the copper, it the researchers mill the flakes into R. Biemmetech is a technologically Netherlands, develops porous extracting the rare earth elements transfers its heat to the metal within a powder, which can then be further oriented company in the sintered ceramic membranes for water from the magnet in a laborious and fractions of a second and solidifies processed. “We press it into its final metal industry specialising in preci- treatment and other technical expensive process. The scientists into flakes. shape,” Diehl added. sion gears and structural parts, applications. A new project has of the Fraunhofer Project Group for If the melted material was allowed A demonstration plant has already stainless steel and bronze PM parts, been started at X-Pore that aims Materials Recycling and Resource to solidify in the normal way the been established. “The demo system including the design and manufac- to combine porous metal filters Strategies IWKS in Alzenau and atoms would line up in rows, in a can process up to half a kilogram of ture of the tooling. Its products are with a ceramic membrane surface Hanau and of the Fraunhofer Institute crystal lattice. In the melt spinning molten material and is somewhere used in the automotive industry and structure. Dr Rinse A Terpstra (middle) with for Silicate Research ISC are now procedure, however, crystallisation between a lab and a large-scale in many other technically demanding www.rbiemmetech.it his wife and daughter receiving the pursuing a different approach. is avoided with either an amorphous plant,” stated Diehl. The researchers applications. www.x-pore.com Fachmetall PM Qualification Award “Instead of trying to regain each structure being formed, in which are now optimising the properties The company’s PM plant estab- www.fachmetall.de from Holger Davin (left) and Dr Georg individual type of rare earth, we focus the atoms are completely irregularly of the recycled magnets by varying lished a sound technology base with Schlieper (right) on recycling the entire material, arranged, or a nanocrystalline the melt spinning process – such as meaning the complete magnet - and structure in which the atoms arrange the speed of the copper wheel or the this in only a few steps,” stated Oliver themselves in nanometer-sized temperature of the melted material Diehl, a scientist in the Project Group grains to form a crystalline structure. during the rapid solidification process. IWKS. “This process is much easier The advantage is that the grain Both influence the cooling rate and and more efficient, because the sizes – meaning the areas with the consequentially also the crystalline composition of the material is already same crystalline structure – can structure of the solidified material. almost as it should be.” be specifically varied and can be www.iwks.fraunhofer.de

First plug-in hybrid transmission from ZF enters volume production

ZF Friedrichshafen AG has “Electrifying the driveline is an announced that its hybrid drive essential means for ZF to further system, incorporating a compact increase efficiency and significantly electric motor and eight-speed reduce emissions,” stated Dr Stefan automatic transmission, has now Sommer, CEO of ZF Friedrichshafen entered volume production and will AG. “As plug-in hybrid vehicles feature in BMW’s X5 xDrive40e. become more prolific, consumers Despite its compact dimensions Vehicles can now be driven are exposed to the performance the electric motor is stated as being purely electrically with zero local capability of hybrid technology in very strong, providing a maximum emissions over comparably long general, for which we expect demand power of 83 kW (113 HP) and a distances and significantly faster, to increase for a long time, and torque of 250 Nm from a standstill. stated the company. As a result, the our plug-in hybrid transmission This allows the vehicle to be driven standard cycle according to ECE 101 in particular. It makes individual purely electrically at a speed of up shows fuel reductions of up to 70% mobility more environmentally to 120 km/h and within a range depending on the capacity of the friendly, more dynamic and also of 31 km. The electric motor is battery system. The BMW X5 will be more sustainable and is completely integrated fully into the transmission the first model to feature the new ZF suitable for everyday use at the same housing and is cooled by atomised oil. plug-in hybrid in volume production. time.” www.zf.com

Sacmi supplies new Rare-earth magnet substitutes hydraulic press to developed at Masdar Institute

PM parts maker Researchers from Masdar Institute of “Rare-earth metals are used in Schunk Science and Technology in Abu Dhabi, many applications requiring strong UAE, are developing novel, low-cost permanent magnets, such as Press manufacturer Sacmi, based magnets with improved magnetic electronics, motors, wind turbines and in Imola, Italy, has announced properties that can withstand high many other high-tech applications,” that Schunk Sintermetalltechnik temperatures to replace expensive added Medraj. “While the entire world GmbH recently installed one of rare-earth magnets commonly used has become dependent on these high- the company’s MPH 200 hydraulic in automotive, aerospace, military tech magnets, over 95% of the global presses at its facility in Thale, and energy industries. production of rare earth materials Germany. Sacmi stated that this is “The novel magnetic materials currently occurs in China. This creates the first solution of this type to be that Masdar Institute researchers a supply risk for many reasons.” installed by Schunk, a specialised are discovering could support the Medraj began his pursuit of Powder Metallurgy parts maker development of next-generation cheaper, high-tech magnets that supplying precision components to clean energy technologies, including do not rely on expensive rare-earth the automotive industry. wind turbines, and have the potential metals while at Concordia University Indutherm Atomiser AU 1000 The MPH 200 press allows the to impact many other key economic in Canada, where he worked for 13 user to make items of complex industries that rely heavily on strong years. He brought his innovative geometry and ensures a dimensional permanent magnets, including research to Masdar Institute a year accuracy up to ± 0.025 mm. The press aerospace and defence,” stated Dr ago and has been rapidly discovering has a compact configuration that Behjat AlYousuf, Interim Provost, new magnetic materials since. In lets users perform all the necessary Masdar Institute. order to discover new combinations PRECISION quality control tasks at high speed “Currently, each megawatt of of various elements that produce and directly in-line. Located at the power generated by a wind turbine magnetic phases, scientists would STRAIGHT TO THE POINT high end of the market in terms of requires up to one ton of rare- try to combine and test different performance, states Sacmi, the press earth magnets. Our research aims amounts of various elements. This offers high precision, reliability and to develop alternative, low-cost method, however, is extremely outstanding productivity. magnets that can reduce the cost of slow and can take several years, as Sacmi has over twenty years’ wind turbines,” stated Dr Mamoun potential combinations are unlimited. Every particle of your precious alloy counts. direct experience in the metal powder Medraj, Professor, Materials Science Medraj’s method speeds the process That‘s why we developped our AU 1000 with field and over 40 years in hydraulic and Engineering, Masdar Institute. up to a couple of months. “We the focus on maximum precision in each detail. systems. The company’s range of Dr Medraj and Post-Doctoral have successfully discovered new MPH presses are claimed to be Researcher Dr Ahmad Mostafa are magnetic phases within different • Effi cient powder production from process start to fi nish technologically advanced yet simple, leading the research. systems and are now in the process • For small batches of metal powder in requested size safe and highly reliable. The press Medraj believes the magnets they of characterising their magnetic • Crucible volume: 1.5 l, optional 0.3 – 12 l design can include either standard are developing will be significantly properties,” Medraj stated. multi plate technology or advanced cheaper and have greater thermal The high throughput screening • Easy-to-clean set-up to avoid metal loss or cross contamination systems such as the patented stability than neodymium based process developed by Medraj • Modular availability of different nozzles to obtain specifi c floating table and the tool-holder magnets, which are the strongest combines thermodynamic modelling metal powder characteristics adapter with concentric plates. rare-earth magnet used today, and continuous diffusion – • Temp. max. 1,600°C, with ceramic crucibles 2,000°C www.sacmi.com making them well-suited for experiments in which two or more • For particle sizes from 10-200 µm and for a wide spectrum demanding, high-temperature elements are continuously diffused, of alloys, e.g. on base of Au, Ag, Cu, Sn, Ni, Fe, Co, Pd... applications such as the power and or combined, at varying amounts. automotive industries. They also can The continuous spectrum formed, • Easy-to-change atomisation nozzle provide the UAE with a potentially which represents the various element • Optional usage of hot gas atomization high-value product in the form of combinations, is analysed and a cheaper magnets. “The problem with magnetic force microscope is used neodymium magnets is that they are to determine if any magnetic phases only good up to 150°C. After that, they exist. demagnetise. While our magnets The newly discovered magnets, might not have the same amount along with the innovative method of magnetic energy as neodymium used to develop them, could result magnets, it is more thermally stable in significantly cheaper and more www.indutherm.de and cheaper in price,” Medraj efficient sustainable technologies. explained. www.masdar.ac.ae

75045 Walzbachtal · Germany · Phone +49 7203 9218-0 · E-mail: [email protected]

GKN demonstrates prototype metal Höganäs boosts New phase-toughened ASCO Sintering to hydride storage tank its Digital Metal ceramic inserts from manufacturer Shift by Wire capacity Greenleaf Corporation components for auto sector GKN Sinter Metals, in Bonn, Vice President Business Development Germany, recently demonstrated its & Advanced Technology - Powder Höganäs AB, Sweden, has announced Greenleaf Corporation, head- ASCO Sintering Co, based in Los Angeles, California, development of hydrogen storage Metallurgy. further investment in its Digital Metal quartered in Saegertown, USA, has announced it will begin supplying a number systems, incorporating metal “We are again demonstrating our facility with the addition of a new Pennsylvania, USA, a leading of new sintered components to a tier one automotive hydride structures produced by leadership in innovation and fully sintering furnace to increase output developer of cutting tool supplier for use in “Shift by Wire” gear systems. Powder Metallurgy, to Germany’s utilising GKN’s competencies in of its 3D printed metal components. technology, has announced The compound gear, output gear, trigger arm, North-Rhine Westphalian Minister of material and production techniques The additional capacity was required that its new XSYTIN™-1 trigger link and couplings are net shape and were Economic Affairs, Garrelt Duin. to bring this pioneering technology to meet the growing demand for 3D phase-toughened ceramic custom engineered and produced using a broad Metal hydrides provide a safe to full production-readiness,” added printed components and offer mate- insert grade is now available spectrum of advanced Powder Metallurgy solutions and and efficient solid state approach Degen. rial alternatives, the company stated. to complement its range of ceramic insert cutting tools. materials ranging from copper infiltrated steel, bearing to hydrogen energy storage. During www.gknsintermetals.com “The new furnace has significantly The company specialises in the manufacturing of grade steel, 316 stainless steel and sinter hardened his visit, Minister Duin was able to increased our production capacity high-performance tungsten carbide and ceramic inserts steel. inspect a prototype of a hydrogen and we are also able to sinter a wider as well as innovative tool-holding systems. XSYTIN™-1 ASCO production processes maintain specification storage tank developed by GKN range of metal powders,” stated Ralf is engineered by Greenleaf to machine more materials and quality levels above 5 sigma for these critical parts together with a partner company. The Carlström, General Manager for than any other ceramic grade in the industry today. It is that are linked to the performance and safety features pilot tank features metal hydrides Additive Manufacturing at Höganäs. designed to mill, turn and groove even the most difficult of the vehicle’s effortless shifting mechanism. All of the made of structures produced by The new high temperature furnace materials on the market at extreme feed rates with the parts have successfully passed PPAP requirements and Powder Metallurgy. offers variable sintering atmosphere high surface footage of ceramic inserts, stated Greenleaf. will be primarily used in luxury higher end vehicles. “Hydrogen will play a central settings and very precise adjustment XSYTIN™-1 is the strongest ceramic insert grade ever The Shift by Wire system is becoming increasingly role in low-emission energy supply of temperature profiles, crucial to produced by Greenleaf and is stated to be ideal for use in popular with OEMs as automotive companies look in the future and this is why GKN is Minister Duin and GKN management the sintering of high quality metal interrupted cuts, removal of scale, roughing, semi-finish for ways to reduce weight, save space, improve working intensively on this trend,” team during a tour of GKN Sinter components. and finish cuts in HRSA materials, cast irons, nodular reliability and better integrate the drive train and shift stated Guido Degen, GKN’s Senior Metals Bonn www.hoganas.com irons, ductile irons, steel alloys and stainless steels. mechanisms into increasingly electronic vehicles. www.greenleafglobalsupport.com www.ascosintering.com Updated Freeman Technology website offers support to powder processors

Powder characterisation specialist enables sensitive QC/QA, more effi- Freeman Technology, based in cient powder processing and effective Tewkesbury, UK, has updated its troubleshooting. website with a number of practical All three of Freeman Technol- supplier for customized powder press systems and automation solutions resources aimed at engineers, ogy’s educational eBooks on the New animation from Freeman Tech- formulators and researchers working fundamentals of powder behaviour nology provides an easy to under- in both the metal powders and and characterisation are also now stand illustration of the mechanisms Additive Manufacturing industries. available for download. The first ‘An of powder flow The website now includes anima- Introduction to Powders’ completion that provides an insight into the ments the animation with a detailed the website has also been updated. testing required for improved powder discussion of powder behaviour and This database provides informa- 100 characterisation as well as the the factors that influence it. tion on powder characterisation for company’s eBook series, covering the The second and third, ‘Choosing all industries and includes a wide 95 fundamentals of powder behaviour a Powder Tester’ and ‘The Value of range of published articles, confer-

and testing. Powder Testing’, discuss how to iden- ence papers and white papers. Its 75 The way in which powders behave tify the best tester for an industrial ongoing development underlines defines their processability and, in application and justify the associated Freeman Technology’s commitment many applications, their value. The investment. Powder testers vary to understanding powder behaviour new animation clearly illustrates considerably in terms of their indus- and to providing powder processors 25 the wide range of variables that trial relevance and ability to deliver with up-to-date, relevant information 5 can influence powder flow and how value and this can have a major to tackle and solve manufacturing

Freeman Technology’s FT4 Powder influence on the return on investment problems. 0 Rheometer can be used to investi- associated with their purchase. www.freemantech.co.uk KE-Line - free programmable, mechanical withdrawal E-Line - new drive technology that was tested under extreme gate their impact. The resulting data Finally, the literature section of press with servo-electric drive for cost eﬀective production www.komage.de conditions in a trendsetting servo-electric ejection press

Powder Metallurgy aluminium components offer lightweight solutions and high volume production The event of the year for anyone involved Powder Metallurgy aluminium components provide design engineers with a lightweight, energy saving option for a range of applications. The process in 3D manufacturing can offer unique material properties along with the ability to produce high volumes of complex aluminium components. Dr.-Ing. Thomas Schubert and Entering its 26th year, SME’s RAPID event plays a Dr.-Ing. Thomas Weissgärber, of Germany’s Fraunhofer IFAM in Dresden, describe the production process and provide a number of industrial case vital role in defining additive manufacturing. It is where studies to highlight the possibilities of aluminium PM. manufacturers and product designers come to explore the newest technologies, product introductions, and materials in additive manufacturing and 3D scanning. No other event provides such a comprehensive display of 3D technology, expertise, and innovation in one place.

Powder Metallurgy applications resistance makes aluminium alloys precision [3-5]. Despite the similarity of lightweight materials, such as attractive for many applications. The to conventional PM processing of Visit alloys of aluminium and titanium, conventional press-and-sinter PM iron-based materials, the sintering are of increasing technological route is a relatively efficient and inex- of aluminium requires very robust and commercial importance. The pensive process, with demonstrated process parameters particularly with rapid3Devent.com produced by Powder Metallurgy process offers capability for producing high volumes regard to tight control of sintering to learn more considerable advantages in the of complex aluminium components atmosphere, temperature and time on-going goal to reduce weight in (Fig. 1) with a reasonable degree of of sintering. transport applications and thereby save fuel. Currently, however, the applications for titanium PM parts COMPANYB are limited to only a few products, EVENT NAME® is produced by SME such as automotive engine intakes and exhaust valves [1, 2]. This is primarily due to the high cost of a titanium component arising from the feedstock as well as the manu- 3D PRINTING EVENT rapid3Devent.com facturing process. Therefore, cost reduction has been the main thrust may 16-19, 2016 | exhibits may 17-19 of current titanium research and orange county convention center | west building development. orlando, fl Aluminium is the second most commonly used metal, following iron and steel, in global production. The combination of low density (2.7 g/cm3) with excellent form- Fig. 1 High volumes of PM aluminium camshaft bearing caps are produced by ability, machinability and corrosion GKN Sinter Metals (Courtesy GKN Sinter Metals)

utectic Al-14Si-2.5Cu-0.5Mg alloy following steps: liquid formation, and the Al-6Zn-2.5Mg-1.7Cu alloy (in particle re-arrangement, solution wt.%) developed by ECKA Granules re-precipitation, grain shape accom- GmbH, Germany, consist of a mix modation, pore-filling and finally of plain aluminium and a master solid state sintering [14, 15]. The alloy powder containing all alloying conventional sintering mechanism elements [7]. This blend design for Al-Cu-Mg, Al-Mg-Si and Al-Zn- results in a higher sintering response Mg-Cu is sintering with an initial compared to the traditional blends. transient liquid phase, which is then Aluminium tends to weld to the transformed to a persistent one at die walls during pressing and this the isothermal sintering temperature. requires the addition of a certain Depending on the selected heating amount of pressing lubricant rate and sintering temperature, the (about 1.5 wt.%), mostly premixed variation in ratio of solid to liquid directly with the metal powders. The parts also influences the shrinkage. problems of dusting and segrega- This very sensitive solid/liquid ratio tion of fine powder mixtures can results in high demands to meet the also be obviated by this lubricant tightly tolerable temperature interval. addition. The use of ethylenbis- However, successful sintering of, for stearamide (EBS) is widespread. instance, Al-Cu-Mg-Si compacts is Most importantly, the lubricant has established industrial practice. to be completely removed prior to Compared to these powder sintering because any remaining mixtures, the hypereutectic Al-Si- carbonaceous products interfere Cu-Mg, alloy developed by ECKA with sintering. To obtain enhanced Granules GmbH, Germany, works in a control of the debinding step in the quite different manner [7]. This is the continuous furnaces typically used, only known Al-Si commercial press- the atmosphere gas composition has and-sinter PM alloy with the nominal Fig. 2 PM aluminium production process [10] (Courtesy GKN Sinter Metals) been successfully analysed in-situ by composition of Al-14Si-2.5Cu-0.5Mg Fig. 3 Varying degrees of complexity can be built into aluminium camshaft Fourier transform infrared spectros- (in wt.%). The incorporated master bearing caps (Courtesy GKN Sinter Metals) Powder production for sinter response and provide sufficient copy (FTIR) [8, 9]. alloy produces a super-solidus liquid mechanical, tribological and physical phase with a persistent character, The sintering atmosphere is Camshaft bearing cap press-sinter generally an important processing properties. Sintering technology which is very sensitive to oxidation Most of the structural PM aluminium The aluminium powder used is by the ambient furnace atmosphere factor for aluminium PM. The best The automotive industry is the most alloys currently used are based on generally produced by air-atomisation The Powder Metallurgy manu- during sintering. The formation of sintered properties of aluminium- lucrative market for PM aluminium, wrought or cast alloy compositions. and has a typical average particle facturing route, involving uniaxial stable Mg oxide surface layers was based compacts are achieved by with the production of structural Materials include ready-to-press size of about 100 µm with an oxygen pressing, dewaxing, sintering and revealed in the case of high oxygen sintering in dry nitrogen, gener- components with remarkable sizing (Fig. 2), allows the near net partial pressures in the nitrogen ally evaporated liquid nitrogen [6, geometrical complexity and high

shape fabrication of precision parts atmosphere used. These oxide 18-21]. A direct reduction of Al2O3 by precision. “powder blends were developed made from many different alloy layers locally hamper the sintering gaseous nitrogen seems unlikely, One part which has increased and designed to both meet an systems. process, resulting in porous surface but magnesium, even in the small the degree of awareness of sintered Sintering is regarded as the most layers with a consequent reduction amounts present in aluminium aluminium within the automotive optimum press-and-sinter response critical step in the aluminium PM in mechanical and wear behaviour. powder, concentrates on the surface market is the camshaft bearing and provide sufficient mechanical, manufacturing cycle. Aluminium has Therefore, the additional control of of powder particles and enhances cap, also known as the cam a high corrosion resistance due to a the oxygen impurities in the furnace sintering by local reduction of Al2O3, cap [27]. These cam caps have been prior to the incorporation of nitrogen produced and employed success- tribological and physical properties” thin surface layer of Al2O3. However, atmosphere is important during the this oxide layer prevents the sintering sintering of this hypereutectic Al-Si- [22-26]. The formation of aluminium fully for more than two decades of aluminium powder particles and Cu-Mg alloy [16]. nitride is thereby an additional key by, for instance, Metal Powder powder blends based on 2014, 6061, content as low as possible (0.2 – cannot be reduced during conven- The mechanism of super-solidus effect, whose role for sintering Products Co (MPP) and GKN Sinter 7075, Al-14Si and AlMCs (Aluminium 0.3%). All alloying elements are intro- tional sintering. Successful sintering sintering was also adapted to blends process is not yet completely under- Metals. Figs. 3 & 4 show examples Matrix Composite) as well as some duced into the ready mixed powders of aluminium alloys can only be based on 7xxx series (Al-Zn-Mg-Cu stood. Obviously, all of these reactions of cam caps of varying degrees

developmental materials to meet as very fine (typically < 45 µm) achieved through the formation of a alloys) [17]. The newly developed 3 Mg + 4 Al2O3 → 3 Al2MgO4 + 2 Al of complexity made by the PM

special customer needs. Fully elemental metal powders or binary liquid phase, which is able to disrupt premix, referred to as ECKA Alumix 2 Al + N2 → 2 AlN aluminium process. Alternatively, pre-alloyed powders cannot be used pre-alloyed powders at near eutectic the stable oxide skins [11]. Copper 431, offers higher strength and better may support diffusion processes these components have been due to their incompressibility and low compositions (e.g. AlSi12, AlMg50) is a well-known alloying element for tensile elongation in the finished in aluminium, which could be respon- manufactured from die cast mate- sintering activity. Therefore, powder containing up to 50% aluminium [6]. liquid phase activation [12, 13]. The parts, due to the higher achievable sible for the shrinkage observed rial, requiring expensive secondary blends were developed and designed In contrast, two commercially avail- liquid phase sintering mechanism sinter density compared to the clas- when a pure nitrogen atmosphere machining to achieve close toler- to both meet an optimum press-and- able aluminium premixes, the hypere- in aluminium alloys involves the sical powder blends. was used. ance features and resulting in

Rotor and sprocket comprises several processing steps: powder compaction, dewaxing at Aluminium PM has found additional 400°C, super-solidus sintering large scale production in automobiles (N2, 550°C, 80 min.), closed die in recent years. The rotor and forging to 100% relative density sprocket used in an automotive (400°C, 700 MPa), heat treatment cam-phaser application (Fig. 5) (470°C, 1h, N2), water quenching are components that are being and aging, blasting and machining. manufactured from aluminium The following material properties powder metal [6, 31]. are achieved: Rm = 335 MPa, Rp0.2 Schwäbische Hüttenwerke = 300 MPa, A5 = 2.5%, hardness HB GmbH (SHW) has developed and = 65-75, fatigue strength = 170 MPa established the conventional (N = 107) [32]. The material offers press-and-sinter route to produce double the contact stress limit and a PM aluminium chain sprocket fatigue strength in a connecting rod, and rotor for selected BMW and compared with the conventional Porsche cam-phaser systems. die-cast aluminium products The company uses a hypereutectic made from, for instance, AlSi15. Fig. 4 PM Aluminium camshaft bearing caps made by Metal Powder Products aluminium-silicon alloy, referred Co for General Motors Powertrain [28] (Courtesy MPIF) The distribution and size of silicon to as Alumix 231, manufactured by particles in the microstructure ECKA Granules GmbH, Germany. have a significant influence on the Fig. 6 Examples of sinter-forged PM aluminium connecting rods [33] higher cost. In contrast, the near characteristics which are quite suffi- The nominal composition of this wear behaviour of the material. (Courtesy JPMA) net shape capability of aluminium cient for this relatively lowly loaded commercial press-and-sinter PM An optimum silicon particle size of PM offers cost savings up to 50%, application. alloy corresponds to Al-14Si-2.5Cu- 25-30 µm was adjusted during the depending on the geometrical GKN has developed and begun 0.5Mg (in wt.%). The resulting parts processing. 3 complexity of the part [29]. shipping initial parts made from PM have a sintered density of 2.65 g/ cm Recently, Hitachi has developed The alloy most commonly used aluminium composites for higher and a relatively homogeneous a new pre-mix powder, based on for cam caps is the PM equivalent performance applications [30]. One microstructure. After heat treatment, Al-Zn-Mg-Cu, referred to as Alumix of the wrought AA2014. The PM application is a marine outboard cam the components have a tensile 431 and manufactured by ECKA process allows the production of cap that requires enhanced strength strength of up to 350 MPa, hardness Granules GmbH, Germany, aimed parts with > 90% density, > 200 MPa and fatigue properties as well as the of >100 HB and elongation of at the substitution of connecting strength and > 80 HB hardness, exceptional wear resistance. 0.5-0.6%. Compared to a standard rods made from the aluminium- sintered iron cam-phaser design, forged alloy that had already been weight is reduced from 900 g to put to practical use (Fig 6) [33]. High 450 g. Additionally, fuel saving is strength is achieved by the Al-Zn- delivered due to the reduced weight Mg-Cu matrix material combined and rotating inertia is also reduced, with a high wear resistance, improving the dynamic response achieved by adding chromium behaviour of the cam-phaser, and boride as hard particles. As a result, thus providing another benefit to the new product has lowered cost engine performance and efficiency. simultaneously with a gain in fatigue These products are now routinely strength of 18% or more, compared Fig. 7 Examples of PM aluminium heat sinks (Courtesy GKN Sinter Metals) fabricated in annual volumes in with a general aluminium-forged 6 excess of 10 units per year. material. a rate of increase is expected for packaging of high performance Connecting rods Heat sinks to continue for the near future. semiconductors. With such progress, problems A heat sink or heat spreader is a Hitachi Powder Metal Co., Ltd. (now Apart from net shape, mechanical arise with heat generation on the device that enhances heat dissipation a subsidiary of Hitachi Chemical Co., and/or triobological properties, semiconductor chips. Actually, from a hot surface, the most typical Ltd.) has developed a powder mixture aluminium PM parts can also be more than 50% of electronic case being heat generated by with the nominal Al-12Si-3Cu-0.5Mg- selected because of their high failures are caused by insufficient components. The heat sink keeps 0.15Ni (in wt.%) alloy for sinter-forged thermal conductivity, which is cooling. To achieve long life and the device temperature below the connecting rods of general purpose necessary for thermal management reliable performance of these specified maximum allowable engines nearly two decades ago. applications. During recent decades, components, it is necessary to keep temperature. Copper or aluminium As a result, 30% thinner and 50% the rapid evolution of integration the operating temperature of an are the traditionally used materials in lighter con rods could be produced, technology has resulted in a electronic device within specified air cooling of electronic components, Fig. 5 PM aluminium VCT sprocket and rotor (Courtesy Schwäbische compared with conventional die significant increase in electronic limits. Therefore, the effective since they offer a solution in reducing Hüttenwerke (SHW) GmbH) cast rods. The production process device density and speed and such thermal management is a key issue the thermal problems.

GKN has developed new PM ceramic additions (e.g. SiC or AlN) to of net shape manufacturing and fine References of Methods of Adding Copper on the [24] K. Kondoh, A. Kimura, Y. Takeda, R. Al-Mg-Sn alloys with high thermal tailor the CTE (Coefficient of Thermal microstructures. For the manufac- Strength of Sintered Aluminum Copper Watanabe, in: Solid-state Sintering of conductivity, in the range of Expansion) and to increase the ture of Al-base PM precision parts [1] T. Saito, The automotive application Alloys, Int. J. Powder Metall. 4 (1968) Aluminium Alloy Powder and Char- 200–250 W/m-K, for heat sink appli- mechanical strength and stiffness by pressing and sintering, suitable of discontinuously reinforced TiB-Ti 37-47. acteristics of Sintered Material, Proc. cations [34]. The combination of low of the heat sink material. Potential powder mixtures have been designed. composites, JOM 56 (2004) 33-36. [13] W. Kehl, H.F. Fischmeister, Liquid Conference ‘Sintering’05’, Grenoble, cost and high thermal conductivity, markets for sintered aluminium are In recent years, remarkable work has [2] M. Qian, Cold compaction and Phase Sintering of Al-Cu Compacts, 2005, 335-338. while being able to provide the shape seen in following applications [34]: been done on Al-Si based sintered sintering of titanium and its alloys for Powder Metall. 23 (1980) 3, 113-119. [25] R.N. Lumley, T.B. Sercombe, G.B. and dimensional capability of PM, is • Transmission Control Modules alloys or particle-reinforced compos- near-net-shape or preform fabrication, [14] R. M. German, Liquid phase Schaffer, Surface oxide and the role attractive to engineers and designers. • LEDs ites. These materials are attractive Int. J. Powder Metall. 46 (2010) 5, 29-44. sintering (New York: Plenum Press) 1st of magnesium during the sintering of These new Thermal Series of low- for wear loaded components, but also aluminium, Metallurgical and Materials • Hybrid vehicles [3] Ch. Lall and W. Heath, PM ed., 1985, p. 1 alloyed sintered aluminium materials offer good mechanical properties and Aluminium Structural Parts – Manufac- Transactions A, 30A (1999) pp. 457-463. • Electronic Steering Modules [15] T. B. Sercombe, Non-conventional offer greater design freedom vs. tailorable CTEs. turing and Metallurgical Fundamentals, sintered aluminium powder alloys, [26] T. Pieczonka, Th. Schubert, S. • ECU/ECM conventional die cast and extruded To date, aluminium PM is still Intern. J. of Powder Metallurgy, 6 (2000) Ph.D. Thesis, The Queensland Univer- Baunack, B. Kieback, Dimensional • IGBT modules products, while eliminating the need a small part of the overall PM 6, 45-50. sity, Australia, 1998 Behaviour of Aluminium Sintered in for machining (Fig. 7). • RF Packages community. Further developments [4] P. Delarbre and M. Krehl, Applica- [16] Th. Schubert, S. Müller, T. Different Atmospheres, Materials At high power levels, and particu- • High Power/High Heat in alloy composition and processing tions of PM Aluminium Parts Materials Weißgärber, B. Kieback, Sintering and Science and Engineering A 478 (2008), larly in applications involving multiple applications. technology, will provide many more and Processing Schemes”, Proc. 2nd Age-Hardening of a Hypereutectic 251–256 prolonged on/off cycles, however, opportunities for the application of International Conference on Powder Aluminium-Silicon PM Alloy, Proc. of [27] J.E. Foss and D. DeFranco, The problems are seen with the reli- PM aluminium. Summary Metallurgy Aluminium Light Alloys for PM2012 - Powder Metallurgy World Northstar Cam Bearing Caps: A new ability of substrate-to-baseplate Automotive Applications, Troy, 2000, Congress & Exhibition Yokohama, Application for Aluminum PM, SAE attachments in high current power The continuing interest in lightweight Authors 33-40 October 14th - 18th, 2012 International Congress and Exposition, modules. Specifically in thermal materials, combined with the need Dr.-Ing. Thomas Schubert and [5] S. Huo, B. Heath and D. Ryan, [17] J. Gradl, H.-C. Neubing and A. SAE Inc., Warrendale, PA, 1994, Tech- cycling conditions, the mismatch for cost efficiency, has provided a Dr.-Ing. Thomas Weissgärber Applications of Powder Metallurgy Müller, Improvement in the Sinterability nical paper # 940429 in coefficient of thermal expansion significant opportunity for aluminium Fraunhofer IFAM Aluminium for Automotive Valve-Trains, of 7xxx-based Aluminium Premix, Proc. [28] P.K. Johnson, 2006 PM Design between the ceramic substrates or PM, particularly in the automotive Winterbergstrasse 28 SAE Int. J. Mater. Manuf. April (2009) 1, EuroPM2004 – Powder Metallurgy Excellence Awards Competition semiconductors of the electronic industry. There exists the potential 01277 Dresden, Germany 511-515 World Congress & Exhibition, Austria, Winners,” Intern. J. of Powder Metal- devices and the copper or aluminium for the aluminium PM industry to Tel +49 351 2537-305 [6] H.C. Neubing, Sinteraluminium – Der October 17th-20th, 2004, vol. 4, 13-20 lurgy, 42 (2006), 4, 17-21. baseplates results in high shear capture additional market share by konsequente Weg vom Pulverprodukt [29] http://www.metalpowder.com/ stresses at the solder joints. A solu- replacement of PM iron parts or cast Email: Thomas.Weissgaerber@ [18] J.H. Dudas, W.A. Dean, The zum Leichtbauteil, Proc. Hagener engineering-solutions/cam-caps tion to this problem involves further aluminium. New PM alloys are being ifam-dd.fraunhofer.de Production of precision Aluminum PM Symposium, FPM, 2004, 3-29 enhancements through the use of developed that utilise the advantages www.ifam-dd.fraunhofer.de parts, Int. J. Powder Metall. 5 (1969)2, [30] http://www.gkn.com/sintermetals/ [7] H.C. Neubing, J. Gradl, and H. 21-36. capabilities/aluminium-pm/news Danninger, Sintering and microstruc- [19] W.J. Huppmann, Sintered [31] A. Pohl, High Wear Resistant ture of Al-Si PM components, in World aluminium parts for automotive appli- Parts of Sintered Aluminium for the Congress on Powder Metallurgy & cations, Proc. 7. Int. Leichtmetallta- Automotive Application, Proc. Euro Inovar Communications Ltd Particulate Materials, Advances in gung, Leoben-Wien, 1981, 236-237. PM2005 - Powder Metallurgy Congress Powder Metallurgy & Particulate Mate- [20] H.C. Neubing, G. Jangg, Sintering & Exhibition, October 2nd-5th, 2005, rials (2002), 128-138 of aluminium parts: the state-of- Prague, 199-204 [8] P. Quadbeck, A. Strauß, S. Müller the-art, Metal Powder Rep. 42 (1987) [32] Z. Ishijima, H. Shikata, H. Urata, and B. Kieback, Atmosphere Monitoring 354-358. S. Kawase, Development of PM forged in a Continuous Sinter Belt Furnace, to [21] M. Qian and B. Schaffer, Sintering Al-Si Alloy for Connecting Rod, Adv. Download all be published in Journal of Processing of aluminium and its alloys, in Sintering Powder Metallurgy and Particulate Technology of advanced materials – fundamen- Mat., 4 (1996), 14-3 – 14-14 [9] P. Quadbeck, B. Schreyer, A. Strauß, tals and processes, ed. by Z.Z. Fang, [33] JPMA 2007 New Materials Category back issues T. Weißgärber, B. Kieback, In-Situ Woodhead Publ. Ltd., 2010, Part III/12, Prize Winner, Hitachi Powdered Metals Monitoring of Gas Atmospheres During 291-323 Co Ltd, JPMA, Japan Debinding and Sintering of PM Steel [22] A. Kimura, M. Shibata, K. Kondoh, [34] R. L. Hexemer Jr., I.W. Donaldson, for FREE Components, Proc. Powder Metallurgy Y. Takada, M. Katayama, T. Kanie, L.B.J. Smith and D.P. Bishop, Develop- World Congress & Exhibition. PM2010, H. Takada, Reduction mechanism ment, properties, and applications for Florence, Italy 10-14 October 2010, of surface oxide in aluminium alloy a High Thermal Conductivity Sintered vol. 2, 239-245 powders containing magnesium studied Aluminium Material, Proc. of Advance- [10] GKN Sinter Metals, PM Aluminium by X-ray photoelectron spectroscopy ments in Thermal Management Confer- Materials brochure, Rev 1.0 using synchrotron radiation, Appl. Phys. ence 2012 held 18./19. September 2012, [11] S. Storchheim, Aluminium Powder Letters 70 (1997) 26, 3615-3617. Denver, Colorado, USA, 123-134 Metallurgy Finally Made Commercially [23] K. Kondoh, A. Kimura, R. Watanabe, practical, Progr. Powder Metall. 18 Effect of Mg on sintering phenomenon www.ipmd.net (1962) 124-130. of aluminium alloy powder particle, [12] T. Watanabe, K. Yamada, Effects Powder Met. 44 (2001) 2, 161-164.

Euro PM2015: Technologies for enhancing the Powder Metallurgy process

A series of papers presented at the Euro PM2015 Congress, held in Reims, France, October 4-7, 2015, looked at the development of a number of design tools for improved control of conventional press and sinter Powder Metallurgy processes. These papers were included in a technical session specifically dedicated to presenting “Tools for Improving PM”. Dr David Whittaker reports on this session for Powder Metallurgy Review and highlights the key developments in this area.

Master alloy additions with high oxygen affinity into low also conferred a number of other alloy sintered steels. The combina- advantages, such as preserving the The first of the papers presented in tion of these elements with other compressibility of the base powder the ‘Tools for Improving PM’ tech- elements with a lower sensitivity for and yielding flexibility in the selec- nical session was one of six keynote oxygen, such as Fe, reduced the risk tion of the final composition by using papers in the congress and related of oxidation during the early stages combinations with different base to the tailoring of the composition of sintering. The master alloy route powders. However, one of the most of master alloy additions. Particular reference was made to the effects of introducing oxidation-sensitive elements and of varying the solubility of the base iron in the generated liquid phase during sintering. The paper was presented by Raquel de Oro Calderon (Technical University of Vienna, Austria) and was co-authored by Christian Gierl-Mayer and Herbert Danninger (also Technical Univer- sity of Vienna) and Elena Bernardo, Monica Campos and Jose Torralba (Universidad Carlos III de Madrid, Spain) [1]. The master alloy route first emerged during the 1970s as a Fig. 1 A busy exhibition accompanied the Euro PM2015 Congress sessions means of introducing elements (Courtesy EPMA)

ware tools has triggered interesting Cu-2Ni-1Si (wt.%), Fraction <45 μm Technique Equipment and Characteristics of the experiment MA1 developments in the design of liquid T = 1073°C, T =1091°C, T = 1120°C solidus liquidus sintering phases, by allowing the identification ThermoCalc® software. Databases: TCFE5 for Fe based master alloys, and SSOL4 Thermodynamic Calculations Ni-4Cu-12Si (wt.%), Fraction <45 μm of low melting point compositions. for Ni and Cu based master alloys MA2 T = 1084°C, T =1127°C, T = 1250°C The author has previously reported solidus liquidus sintering DSAHT furnace (KRÜSS) equipped with an observation window and a recording on advances in the design of master Wetting Experiments system. Atmospheres: Ar and N -5%H (Purity 99.9%). Videos recorded during Fe-40Mn-15Si-1C (wt.%), Fraction <45 μm alloy compositions that present a 2 2 MA3 continuous heating at 5°/min heating rate up to 1200°C Tsolidus= 1060°C, Tliquidus=1072°C, Tsintering= 1250°C methodology for prediction, from the early stages of the design, important STA: Differential Thermal Netzsch STA 449 C Table 1 Characteristics of the powdered liquid phase promoters used in this features of the liquid such as its Analysis and Thermogravimetry Experiments in Ar atmosphere. 1500°C, Heating/Cooling rate 20º/min study. T represent the expected sintering temperature. T and T sintering solidus liquidus wettability, infiltration capability and Netzsch 402 C dilatometer were measured by DTA (in Ar) [1] Dilatometry dissolutive character. Experiments in H2 atmosphere. 1370°C, Heating rate 10º/min In the work reported in this paper, Quadrupol mass spectrometer Netzsch QMS 403 Aeölos interesting benefits of using master does, however, introduce important three different master alloy systems Mass Spectrometry Coupled by a quartz capillary with STA and dilatometer. Allows the analysis of the alloys is the fact that their composi- challenges, such as maintaining were compared, a low dissolutive gaseous species evolved during the thermal treatment tion can be specifically designed for proper dimensional control and Cu-based master alloy (MA1) and DT1000 Adamel Lhomargy quenching dilatometer the particular purpose of forming minimising the effect of secondary two systems (MA2 and MA3) with Step Sintering Experiments Atmosphere: He, Heating rate 10°/min, Cooling rate ~ 100°/s a liquid phase that enhances the porosity on the final performance of a higher degree of iron dissolution distribution of alloying elements and the steel. but different contents of oxidation- Table 2 EuroSummary PM2015 of the differentTools for experimental Improving techniques,PM equipment and characteristics of the experiments [1] accelerates the sintering mecha- Over the past decade, the use of sensitive elements. The compositions nisms. Working with a liquid phase thermodynamic and kinetic soft- and melting temperatures of these Fe - 4Cu Fe - 4MA1 (Cu-2Ni-1Si) Low Dissolutive Cu dL/Lo /% dL/Lo /% 3.5 3.5

1080°C 1085°C 1095°C T =1120°C 2.5 2.5 sintering Ar 1.9 % Ar 1.9 % H2 1.9 % 1.5 H2 1.8 % 1.5

0.5 1.3 % Ar 0.5 Ar 1.3 % H21.1 % 1 % H2 -0.5 -0.5 200 400 600 800 1000 1200 200 400 600 800 1000 1200

Low Dissolutive MA1 Fe - 4MA2 (Ni-4Cu-12Si) Fe - 4MA3 (Fe-40Mn-15Si-1C)

1075°C 1085°C 1095°C dL/Lo /% dL/Lo /% Tsintering=1120°C 3.5 3.5

2.5 Ar 0.79 % 2.5 Ar 0.85 % H2 0.78 % H2 0.85 % Ar 1.1 % 1.5 H2 1 % 1.5

0.5 0.5 Ar 1.2 % H2 1.1 % -0.5 -0.5 200 400 600 800 1000 1200 High Dissolutive MA2 200 400 600 800 1000 1200 Fig. 7 Dilatometry on green compacts pressed at 600 MPa for samples without graphite. 1090°C 1100°C 1120°C Tsintering=1250°C Fig. 3 Dilatometry on green compacts pressed at 600 MPa for samples without graphite. Experiments in Ar and Experiments in Ar and pure H2. pure H2 [1] Fe -0,5C- 4Cu Fe -0,5C - 4MA1 (Cu-2Ni-1Si)

three masterdL/Lo /% alloys are given in comparisons of microstructuraldL/Lo /% of the alloying elements and very

3.5 Ar 1.6 % 3.5 Table 1. MA3 is seen to contain evolution are presented here homogeneousAr microstructures.1.3 % H2 1.3 % H2 1.3 % a much higher2.5 level of oxidation as Fig. 2 and of the observed2.5 The excellent infiltration ability of 1.5 % Ar 1.6 % Ar sensitive elements (Mn and Si) than dimensional changes, characterised theseH2 1.4 liquids % causes a significant High Dissolutive MA2 1.5 H2 1.4 % 1.5 MA2. The experimental techniques, by dilatrometric studies, as shown swelling effect on forming liquid, 900°C 1185°C 1195°C 0.5 0.5 Tsintering=1250°C equipment and characteristics of in Figs. 3 to 5. On the basis of these however. With these types of liquids, -0.5 -0.5 the experiments,200 used to400 study600 the 800 results,1000 the1200 authors have proposed200 400 the600 dimensional800 1000 stability1200 of the parts effects of using these three master a number of general conclusions, as seems to be more sensitive to those alloy types, are summarised in follows. parameters that affect the wetting Table 2. Fe -0,5C - 4MA2 (Ni-4Cu-12Si)Non-dissolutive or lowFe dissolutive-0,5C - 4MA3 behaviour (Fe-40Mn of- the15Si liquid,-1C) such as the

The resultsdL/Lo /% from the full range liquids (Cu and MA1)dL/Lo have /% a high sintering atmosphere or the presence

of experiments3.5 can be found by ability to infiltrate and3.5 distribute of carbon. Fig. 2 Microstructure evolution in steels containing Fe+0.5 wt. %C with 4wt.% addition of Cu, MA1, MA2 or MA3. reference to the full paper, but the through the iron pore skeleton, Liquids with a highly dissolutive 2.5 Ar 0.43 % 2.5 Ar 0.69 % H2 H2 0.53 % Experiments in static He atmosphere [1] significant results in relation to giving 0an.48 % optimum distribution behaviourAr 1.5 % (MA2 and MA3) tend to Ar 1.4 % 1.5 1.5 H2 1.3 % H2 1.2 %

0.5 0.5 46 © 2015 Inovar Communications Ltd © 2015 Inovar Communications Ltd 47 Powder Metallurgy Review Winter 2015 -0.5 -0.5 Winter 2015 Powder Metallurgy Review 200 400 600 800 1000 1200 200 400 600 800 1000 1200

Fig. 8 Dilatometry on green compacts pressed at 600 MPa for samples with graphite. Experiments in Ar and pure H2.

It is impossible to directly extrapolate the influence of the reducing agents observed in macroscopic wetting experiments to the conditions in a green compact. Especially in the case of the atmosphere, it should be considered that in a green compact the atmosphere only has limited access to the internal pore network, and a microclimate is created inside the closed pores. This explains the lack of differences when only H2 is used as a reducing agent. Carbon is therefore an essential additive, on one hand because it can promote the reduction by carbothermal reactions even inside the microclimate created inside the isolated pores. And on the other hand because reduction of more stable oxides for which higher temperatures are needed- will always be assisted by carbon, which is the most effective reducing agent at higher temperatures.

9 Euro PM2015 Tools for Improving PM

Fe - 4Cu Fe - 4MA1 (Cu-2Ni-1Si)

dL/Lo /% dL/Lo /% 3.5 3.5

2.5 2.5 Ar 1.9 % Ar 1.9 % H2 1.9 % 1.5 H2 1.8 % 1.5

0.5 1.3 % Ar 0.5 Ar 1.3 % H21.1 % 1 % H2 -0.5 -0.5 200 400 600 800 1000 1200 200 400 600 800 1000 1200

Fe - 4MA2 (Ni-4Cu-12Si) Fe - 4MA3 (Fe-40Mn-15Si-1C)

dL/Lo /% dL/Lo /% 3.5 3.5

2.5 Ar 0.79 % 2.5 Ar 0.85 % H2 0.78 % H2 0.85 % Ar 1.1 % 1.5 H2 1 % 1.5

Fig. 7 Dilatometry on green compacts pressed at 600 MPa for samples without graphite. Experiments in Ar and pure H2. interest is growing in the PM industry Fe -0,5C- 4Cu Fe -0,5C - 4MA1 (Cu-2Ni-1Si) in alternative methods for numeri- dL/Lo /% dL/Lo /% cally analysing these effects, with 3.5 Ar 1.6 % 3.5 Ar 1.3 % H2 1.3 % H2 1.3 % the discrete element method (DEM) 2.5 2.5 1.5 % Ar 1.6 % Ar emerging as the most promising H2 1.4 % 1.5 H2 1.4 % 1.5 approach.

0.5 0.5 The study began with the genera-

-0.5 -0.5 tion of experimental evidence Fig. 6 Sand sample. Dry (left) and wet (right) sample [2] 200 400 600 800 1000 1200 200 400 600 800 1000 1200 showing void formation near to the die walls. Sand grains and metallic Fe -0,5C - 4MA2 (Ni-4Cu-12Si) Fe -0,5C - 4MA3 (Fe-40Mn-15Si-1C) powder were tested in a cylindrical die using a vertical pouring meth- dL/Lo /% dL/Lo /% Euro PM2015 Tools for Improving PM odology. For the sand grains, a 3.5 3.5 non-cohesive sample with particle 2.5 Ar 0.43 % 2.5 Ar 0.69 % H2 H2 0.53 % 0.48 % Ar 1.5 % diameter ranging from 100 μm Ar 1.4 % 1.5 1.5 H2 1.3 % H2 1.2 % to 350 μm was first tested (Fig. 6 Fig. 7 Left, CFY powder sample is shown. Centre, molybdenum powder sample. 0.5 0.5 left). To increase cohesion, 4 wt% Cavities in the molybdenum sample in detail (right) [2]

-0.5 -0.5 of water was then added. Results 200 400 600 800 1000 1200 200 400 600 800 1000 1200 with this powder sample are shown in Fig. 6 right. The formation of Fig. 4 Dilatometry on green compacts pressed at 600 MPa for samples with graphite. Experiments in Ar and pure H [1] cavities in this sample was noted. Fig. 8 Dilatometry on green compacts pressed at 600 MPa for samples with graphite. Experiments 2 in Ar and pure H2. These cavities extended, in most cases, by many particle diameters in particular its wetting capability, It is impossible to directly extrapolate the influence of theAr reducingH2 agents observed in macroscopic from the near wall. In a second step, which in turn could affect the sensi- wetting experiments to the conditions in a green compact. Especially in the case of the atmosphere, it metallic powder was then assessed. 2 should be considered that in a green compact the atmosphere only has limitedtivity ofaccess the dimensionalto the internal stability to Fig. 7 left side shows a sample of 1,8 pore network, and a microclimate is created inside the closed poresthe. This processing explains atmosphere. the lack of 1,6 differences when only H2 is used as a reducing agent. Carbon is therefore an essential additive, on a non-cohesive powder. A similar Fig. 8 Stable cavity region displayed in detail. Left, particles are displayed in 1,4 one hand because it can promote the reduction by carbothermal reactions even inside the behaviour to the dry sand sample detail. Right, force chains are depicted. Particle bed was cut in the centre plane 1,2 microclimate created inside the isolated pores. And on the other hand Simulatingbecause reduction the dieof more filling was observed, with no cavities being for visualisation [2] stable oxides for which higher temperatures are needed- will always be assisted by carbon, which is 1 process formed in the visible, near wall the most effective reducing agent at higher temperatures. 0,8 regions. Fig. 7 middle shows the 0,6 Attention was switched from powder results with a molybdenum powder 9 0,4 design to the numerical simula- sample. The molybdenum powder 0,2 tion of the die filling process in a is very cohesive and has an average 0 paper presented by Daniel Schlochet diameter of 4.6 μm. In Fig. 7 right, the Nasato (Johannes Kepler University, molybdenum sample is shown from a Austria) and co-authored by Stefan different angle to show the cavities in Pirker and Thomas Lichtenegger more detail. Fig. 5 Dimensional Change during heating in the temperature range between (also Johannes Kepler University) The study was then continued 1000-1370°C [1] and Christoph Kloss (DCS Computing through numerical simulation GmbH, Austria) [2]. In the reported (using the DEM approach) of powder pouring in die filling, remain locally concentrated around Special attention should be paid work, a numerical study of the effects (a) (b) the location of the primary master when using master alloys with a of cohesive forces on the formation varying process variables (shaking alloy particles. Dissolution of the high content of oxidation-sensitive and stability of cavities or holes in the and pouring methodologies) and surrounding iron base particles alloying elements. Despite the die filling process was carried out. material properties (degree of decreases the liquid’s ability to dissolutive behaviour of MA3, the A consistent and uniform die cohesion and particle size). In the distribute through the pore network dimensional stability in Fe-C-MA3 filling process is always desirable. described analysis, to reduce the number of particles having similar CONCLUSIONSand this lead to heterogeneous steels is sensitive to the atmos- Heterogeneity during die filling physical behaviour, a coarse graining -Non- dissolutivemicrostructures. or low dissolutive In this case, liquid s (liquid phasephere.s which Withdissolves this typeonly smallof master amounts alloy, of iron) can propagate through the subse- presentthe final a high properties ability to infiltrate could andbe distribute throughthe differencesthe iron pore inskeleto chemicaln, giving activity an optimum quent processes and finally lead to methodology was adopted and a distribution of the alloying elements and very homogeneous microstructures. The excellent particle size of 1 mm was used. In infiltrationexpectedability to beof themorese liquidsensitives causes to a significantbetweenswelling baseeffect ironupon powders liquid formation and . With serious product defects, such as thesethe types use ofof fineliquids, andthe welldimensional dispersed stability of masterthe parts alloyseems powders to be more can sensitive cause anto those cracking, low strength, distortion the numerical simulations, material parametersmaster alloythat affect powdersthe wetting in thebehavior mix. of the liquid,oxygensuch transfer as the fromsintering the atmosphere surface or the and shrinkage. A poor initial granule was poured into a simple cylindrical presence of carbon. In contrast to the low dissolutive of the iron base particles to the packing can also create “arching” die using different values for cohesive (c) (d) -Liquids with a highly dissolutive behavior tend to remain locally concentrated around the location of forces. Particles were removed the(infiltrating) primitive master liquids, alloy particles. dissolutive Dissol ution of thesurface surrounding of theiron master base particles alloys. Thedecreases its defects. However, it is virtually abilitymaster to distribute alloys throughprovide the significantly pore network which wouldchangelead in to theheterogeneous surface chemistry microstructures . In impossible to measure density gradi- in a semi-spherical region with a Fig. 9 Evolution of porosity with time for different cohesion values. (a) hori- this case, the final properties could be expected to be more sensitive to the use of fine and well diameter of 5 particles diameters zontal, (b) vertical, (c) combined in-phase and (d) combined off-phase vibration dispersedlower dimensionalmaster alloy changespowders in upon the mix. In contrastof the masterto low dissolutivealloy particles (infiltrating) can liquids, ents and free surfaces of powder formation of the liquid phase. modify the behaviour of the liquid, beds in the as-filled state. Therefore (Dp) in the bottom region of the modes [2] 10

modes are shown. The collapse of The region near the small internal the cavity for the combined off-phase cylinder was also investigated. movement and an increase in Fig. 13 shows the porosity values for packing for the combined in-phase low cohesion (0.2 J/m2). Fig. 13 left are demonstrated. In Fig. 10 right, corresponds to vertical pouring and the porosities for cohesion values Fig. 13 right corresponds to inclined of 1.6 J/ m2 are shown. The collapse pouring. Fig. 14 shows the porosity of the cavity could not be predicted, values for intermediate cohesion but an increase in packing for the (0.4 J/m2). Fig. 14 left corresponds combined movements was noted. to vertical pouring and Fig. 14 right In the die filling process, the side to inclined pouring. The results effects of different process and are very similar to those for the large Fig. 13 Low cohesion case. Porosity was calculated near the small cylinder material variables in the packing cylinder porosity with respect to the region. Left corresponds to vertical pouring and right side corresponds to inclined pouring [2] Fig. 10 Evolution of porosity with time for different vibration modes. In the region were evaluated through the shaking modes. left side, cohesion value of 1.2 J/m2 and in the right side cohesion value of simulation of the powder pouring Overall, the simulation results 1.6 J/m2 [2] process. Two die configurations showed a correlation between were analysed: one consisting of a shaking mode, pouring method cylinder without any internal tool and material properties and the elements and the second consisting conclusion was drawn that one of this same cylinder but with a should consider the combination of small cylinder inside. The external the process variables and material cylinder had a diameter of 50 mm properties when optimising the die and the internal cylinder a diameter filling process to reduce material of 20 mm. Both configurations were density gradients. tested for varied pouring (vertical and Fig. 11 Inclined pouring and no internals. Left is the initial state and right is the inclined), vibration mode (vertical, Fig. 14 High cohesion case. Porosity was calculated near the small cylinder final state [2] horizontal, combined in-phase Monitoring of shrinkage region. Left corresponds to vertical pouring and right side corresponds to and combined off-phase), particle during the sintering process inclined pouring [2] cohesion and size. The focus then switched to the The tested die filling configuration Sample sintering process in a paper from can be seen in Figs. 11 and 12. From Fused quartz glass Infrared reflector these results, it can be concluded Torsten Staab and Andreas Diegeler Telecentric lenses that inclined pouring has a negative (Fraunhofer Institute for Silicate impact on the initial arrangement Research, Wurzburg and University of Wurzburg, Germany). This paper of the material, with high porosity CMOS camera Fig. 12 Vertical pouring and internals. Left is the initial state and right is the values. After the shaking process, the demonstrated the viability of using a Halogen lamp final state[2] thermo-optical measurement device porosity is reduced to similar values, Sample holder on comparing the same variables, for or optical dilatometer (TOM-AC) PID controller cylinder to form a stable cavity. The significant number of points per the vertical and the inclined pouring to follow sintering shrinkages in a cylindrical die was then shaken, particle in the region of interest. cases. number of powder metallurgical samples of unusual shape. Fig. 15 A schematic view of the thermo-optical measurement device TOM-AC using a frequency of 200 Hz (F200) and These points were generated in A similar behaviour was seen in amplitude of 1e-4m (this corresponds a random way and porosity was the case with the internal tooling Employing an optical dilatometer at the Fraunhofer ISC (right) and diode light source with Ulbricht sphere (left): to Dp/5).The acceleration force calculated by the ratio of points element and is more pronounced having an inspection window of Samples are placed inside a furnace enclosed by a vacuum vessel. This allows -5 resulting from the shaking process inside / outside of the particles. in the higher cohesion cases. This 50 mm in diameter offers the for a vacuum of better than 10 mbar. The sample is illuminated from the left was normalised with respect to local Fig. 9 shows the evolution of the can be explained by the formation possibility of monitoring changes in while the CMOS-camera placed to the right detects its shape [3] minimum and average force chains in porosity with time for the different of stable heaps of material (Fig. 11), the shape not only of several samples the cavity region. Vertical, horizontal, shaking modes. The worst results which leads to an uneven distribution at the same time but also at different possible. The vacuum vessel has silhouette inside the furnace from combined vertical and horizontal were obtained with horizontal of material in the die region. regions of all samples, for example two cylindrical openings on the the right (see Fig. 15). The improved movement in-phase (resulting in shaking (left). Only for 0.1 J/m2 When comparing the shaking their width, height or surface. Even optical axis, which are equipped version of TOM-AC has a light a vertical inclined movement) and and 0.2J/m2, could the collapse of modes, it was noted that, for lower though more precise, a conventional with optical flanges (quartz glass) source equipped with a diode-array combined vertical and horizontal the cavity be predicted. Fig. 9 right cohesion cases, the vertical and dilatometer does not offer these located at 180°, allowing the sample illuminating an Ulbricht sphere and, movement off-phase (resulting in a corresponds to a combined off-phase horizontal vibration resulted in lower options. to be viewed. Quartz glass is used therefore, the distribution of the light circular movement) were simulated. (circular) movement and, for this porosity, in comparison with the TOM-AC, the optical dilatometer due to its low thermal expansion is much more homogeneous than The evolution of porosity in the case, the collapse of the cavity could combined (in-phase and off-phase) employed in this study, consists and good heat resistance. Employing in a previous version. Due to the cavity region with time (Fig. 8) was be demonstrated for cohesion values vibrations. On the other hand, for the of a cylindrical vacuum vessel temperatures below 1300°C (low even illumination with short wave defined through a Monte Carlo as high as 1.2 J/m2. In Fig. 10 left, high cohesion case, the combined containing a metallic Mo-heater, temperature range), the sample is length (blue) light over the whole integration method. This method the porosities for cohesion values (in-phase and off-phase) vibrations making measurements under illuminated from the left, while the diameter d = 50 mm of the optical consisted of generating a statistically of 1.2 J/m2 using different shaking led to significantly lower porosity. reducing or inert gas conditions CMOS-camera detects the sample’s flange, the accuracy was improved.

rate has its maximum at about 770°C, when the carbothermic reaction of removing the oxides is most active [5]. The reduction of the oxides – supported by the hydrogen-containing atmosphere – makes the shrinkage possible manifesting in the high shrinkage rate observed at 770°C. At temperatures higher than 1300°C Water Ar blanket 100 Astaloy CrM Test 1 (high temperature range) the sample 90 Cathode is self-luminous and the diode- 80 array is switched off. Fig. 15 shows 70 Mn O-ring seal a schematic of the experimental 60 Mo Si set-up. Argon Cathode 50 O Anode Averaging over 150 frames, the 40 Ni software corrects imaging errors, 30 Cr

Sample (weight%) Mass fraction such as noise and thermal flickering, 20 S Fe while, at the same time, the exposure 10 time is adapted to the brightness. 0 Water 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 So, the contrast is enhanced by Depth nm Figure 5: Carbonyl iron sphere heated with 3 K/min up to 650°C, holding for 60min and heating then keeping it within the dynamic range Isolator Fig. up16 to Carbonyl 1240°C with 2iron K/min: sphere Shrinkage heated (blue dots) at recorded 3 K/min by TO upM- ACto and650°C, smoothed held values for (orange 60 min line) employing a moving average algorithm. From the smoothed shrinkage curve (orange) the of the CMOS-sensor. Temperature is Fig. 19 A schematic illustration of a Grimm glow discharge Fig. 20 Depth profile of the surface film on Astaloy CrM and numericalthen heated derivative to has 1240°C been obtained at 2 K/min:(green dots) Shrinkage and again smoothed (blue dots)by a moving recorded average by(red line). A correction for thermal expansion is done assuming a linear behaviour as recorded up to 500°C. controlled using a PID controller. TOM-AC and smoothed values (orange line) employing a moving average algo- source [4] powder [4] All CMOS-camera pictures are rithm.IV. From METALLIC the smoothedFOAM: STAINLESS shrinkage STEEL curve (orange) the numerical derivative analysed in real-time, using software has Inbeen this section obtained we present (green an example dots) of and metallic again foam smoothedsamples consisting by aof moving430L X6Cr17 average stainless (red 100 Astaloy CrM -Test 1 and 2 14 316L Test 1 steel powder. The large porosity of the sample can be seen from figure 4 – middle – by the light (developed at the Fraunhofer ISC) line). A correction for thermal expansion is done assuming a linear behaviour, shining through the sample’s edges. employing a Monte-Carlo algorithm, 90 as recordedNo shrinkage up was to detectable 500°C up[3] to a temperature of 1050°C. However, significant shrinkage occurred 12 at higherEuro temperaturesPM2015 – Tools and for around Improving 1180°C PM the maximum of the shrinkage rate is observed just before 80 the holding time is reached at 1250°C (shown in figure 6). As described in the previous section, the to determine the sample’s contour 70 10 Mn shrinkage curve has been smoothed and the derivative taken to obtain the shrinkage rate, which with the smallest possible systematic worked – as shown in figure 6 – even for the very irregular shape of the metallic foam. 60 O Mo 8 The principal trends of shrinkage and shrinkage rate are very similar to those data for the same error. The software records the Cr Si material taken in a conventional dilatometer – see e.g. [6]. 50 Fe O relative change of the sample’s width 6 40 O Ni or height ε = L/L within the chosen 0 30 Cr 4 Cr Mass fraction (weight%) Mass fraction Mass fraction (weight%) Mass fraction S windows and also stores the pictures 20 Fe 2 Fe taken. 10 The first sample type reported 0 0 was a metallic sphere, consisting 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 Depth nm Depth nm of high purity carbonyl iron after binder burn-out. The shrinkage and Fig. 21 Depth profile of the surface film on 316L powder[4] Fig. 22 Small elemental enrichments at the top of the shrinkage rates are shown in Fig. 16. surface oxide film on 316L powder [4] From the smoothed shrinkage curve the numerical derivative has been obtained and again smoothed by a for the very irregular shape of the during the heat treatment has Sophie Caddeo-Johansson (Sandvik sliding average (9 data points), see metallic foam. The principal trends accuracy high enough not only to Coromant, Sweden) and Dimistris Fig. 17 FigureMetallic 5: Metallic foam foam sample sample consisting of 430L of X6Cr17430L stainlessX6Cr17 steel stainless powder: The steel shrinkage powder: curve shown is for a width window in the middle of the sample. The heat treatment employed a Fig. 16. As can be seen, not only of shrinkage and shrinkage rate obtain reasonable shrinkage curves, Chasloglu (Höganäs AB, Sweden). The shrinkagegraphite heater curve under shown Ar-gas containing is for a6.5% width hydrogen. window We did innot the apply middle any correction of the for thermal sample. expansion. was a reasonable shrinkage curve were very similar to published data but also to determine shrinkage The surface characteristics of the The heat treatment employed a graphite heater under Ar containing 6.5% V. SCREEN PRINTED STAINLESS STEEL obtained, but also the numerically for the same material, taken using a rates by numerical derivatives of powder particles play a key role in the hydrogen. No correction for thermal expansion was applied [3] Euro PM2015 – Tools for Improving PM Here, we present our investigation on screen printed grids from stainless steel (316L). De-binding has derived shrinkage rate showed that conventional dilatometer. the shrinkage data. This provides processing of powders into consoli- been performed with a heating rate of 3 K/min inside a separate furnace in three steps under nitrogen containing 5% hydrogen: 300, 500 and 650°C with employed holding times of 30, 30 and 60min, the onset of shrinkage was just below Finally, stainless steel (316L) the possibility of using the optical dated products, not least in sintering respectively. The samples were then transferred to the TOM-AC and sintered there under the Ar 600°C, while the shrinkage rate screen printed grids were detection of PM samples in, for where initial reduction of surface atmosphere containing 6.5% hydrogen up to 1350°C. For more details of the measurement we refer to [4]. had its maximum at about 770°C, investigated. In previously debound instance, the TOM-AC, while, at the oxides is an important consideration, The onset of the shrinkage is about 1050°C while the maximum of the shrinkage rate is found to be at 1250°C. Only few data on shrinkage rates for stainless steel samples exist. However, in [6] chapter when the carbothermic reaction of samples, the onset of shrinkage was same time, the detection of warping and on the final properties achieved 3.4.2 a similar behaviour of the 316L-sample has been found: the onset of shrinkage above 1000°C and a maximum of the shrinkage rate at 1250°C. removing the oxides is most active. observed to be at about 1050°C while during the sintering process is also for the material. Characterisation of Hence, we can state the optically recorded data is good enough to allow for a sophisticated data analysis obtaining the shrinkage rate as well. The second set of samples was the maximum shrinkage rate was possible. surface oxide films by techniques, metallic foams, consisting of 430L found to be at 1250°C (Fig. 18). Few such as XPS or TEM/EDS, provides X6Cr17 stainless steel powder. No published data on shrinkage rates for reliable information on the surface Characterisation of surface shrinkage was detectable up to a stainless steel samples exist, but, in films, but these techniques are time- temperature of 1050°C. However, one data source, a similar behaviour oxide films consuming and the analysed areas significant shrinkage occurred at of the 316L samples has been found; are extremely limited. In this reported higher temperatures and, around the onset of shrinkage above 1000°C The final paper in the ‘Tools for study, the potential of depth profile 1180°C, the maximum shrinkage and a maximum shrinkage rate at Improving PM’ technical session analysis by Glow Discharge Optical rate was observed just before the 1250°C. continued the consideration of Emission Spectroscopy (GD-OES) has Figure 6: Shrinkage for a grid produced by a screen printing process of stainless steel measured by Fig. 18our ShrinkageTOM-AC: Placing for the a measurement grid produced windows by for athe screen total area printing (Fig. 4 - right process) the corresponding from stain - holding time was reached at 1250°C Overall, the reported work sintering issues and was presented been evaluated for Astaloy CrM and shrinkage is obtained. The original area has been normalized to 1. A correction for thermal expansion less steelis done measuredassuming a linear using behaviour the as TOM-AC recorded up tosystem. 500°C. Placing the measurement (Fig. 17). As described previously, has shown, for several powder by Irma Heikkila (Swerea KIMAB 316L powders.

windowsVI. CONCLUSIONSfor the total area, the corresponding shrinkage is obtained. The the shrinkage curve was smoothed metallurgical samples, that the AB, Sweden) and was co-authored The glow discharge source original area has been normalised to 1. A correction for thermal expansion is and the derivative taken to obtain the optical detection system for by Christer Eggertson and Mats commonly used in depth profiling We have shown for several powder metallurgical samples that the optical detection system for made,monitoring assuming dimensional a linear changes behaviour during the heat as treatment recorded has an up accuracy to 500°C high enough [3] not only to shrinkage rate, which worked even monitoring dimensional changes Randelius (also Swerea KIMAB), consists of an anode tube and the obtain reasonable shrinkage curves, but also to determine shrinkage rates by numerical derivatives of the shrinkage data. This provides the possibility to use the optical detection of PM samples in, e.g., TOM-AC, where at the same time also a detection of warping during the sintering process is possible.

52 PowderACKNOWLEDGEMENTS Metallurgy Review Winter 2015 © 2015 Inovar Communications Ltd © 2015 Inovar Communications Ltd Winter 2015 Powder Metallurgy Review 53 We would like to thank the group of Prof. B. Kieback – especially Dr. P. Quadbeck (Fraunhofer IFAM Dresden) for discussions and for providing the powder metallurgical products investigated.

REFERENCES

01 Friedrich G. Raether. Current state of in situ measuring methods for the control of firing processes. Journal of the American Ceramic Society, 92 (2009) 146–152 02 F. Raether, J. Meinhardt, P. Schulze Horn. TOM – a versatile thermo-optical measuring system for the optimization of heat treatments. CFI-Ceram. Forum Int. 84 (2007) E18 03 T.E.M. Staab, J. Müller, D. Winkler, A. Diegeler. New Developments in Thermo-Optical- Measurement Devices. Proceeding of EURO-PM 2011 (Barcelona) 04 A. Diegeler and T.E.M. Staab. Thermo-Optical Measurement Techniques. To be published in Proceedings of Sinterning 2014, Dresden. 05 H. Danniger and C. Gierl. New Alloying Systems for Ferrous Powder Metallurgy Precision Parts. Science of Sintering 40 (2008) 33-46 06 Jiupeng SONG. Experiments, Modelling and Numerical Simulation of the Sintering Process for Metallic or Ceramic Powders. PhD-Thesis Shanghai Jiaotong University, China 2007. AMPM2016_AD_A4_Layout 1 8/25/2015 1:30 PM Page 1

sample to be analysed. The source single atoms into the negative glow, materials. However, more investiga- is generally named a Grimm type of where they are diluted in the argon tion is needed before GD-OES depth glow discharge lamp (Fig.19). The flat carrier gas. All the elements at the profiling can be fully established as a sample is placed perpendicular to the sample surface are sputtered at the surface analysis method for powder front of the anode tube, which is kept same rate as soon as the equilib- materials. at ground potential. Electrical power rium conditions for the plasma are is supplied directly to the sample. achieved after the plasma ignition. Author Additive Manufacturing A distance of about 0.1-0.2 mm is The quantification of GD-OES kept between the sample and anode signals is relatively uncomplicated, David Whittaker tube. Sufficient vacuum tightness is giving quantitative information on the DW Associates with Powder Metallurgy achieved by an O-ring, which sepa- content of several species. GD-OES 231 Coalway Road, Wolverhampton rates the discharge chamber from is able to analyse surfaces varying WV3 7NG, United Kingdom the air environment. from a few nanometers to 100 μm. Tel: +44 (0)1902 338498 June 5–7 • 2016, Boston, MA When the plasma is ignited The elemental concentrations range Email: [email protected] inside the plasma chamber, free from 0.001 % to 100% (mass frac- electrons and a plasma are gener- tion). The limitation of the technique References ated. Both species will move freely is that it lacks lateral resolution. The in the electrical field controlling the analytical data is averaged over the [1] Tailoring Master Alloys for Liquid plasma chamber and will influence area defined by the inner diameter Phase Sintering: Effect of Introducing the electrical field through creation of of the hollow anode, typically 4 mm. Oxidation-Sensitive Elements, R local charge distributions. Different Depending on the application, this de Oro Calderon, C Gierl-Mayer, H characteristic areas are formed in can be an advantage or a disadvan- Danninger, E Bernardo, M Campos the plasma. Two of these are funda- tage. and J Torralba, as presented at Euro mental to the use of glow discharge In the reported results, it was PM2015, Reims, France, EPMA, UK for analytical purposes; namely, the shown that GD-OES displays a thick- [2] Numerical Simulation of Porosity negative glow, free of electrical field ness of 5 nm for the oxide film on of Cohesive Powders after Die Filling but showing high charge density Astaloy CrM powder. The composition Process in Dependence of Different for both ions and electrons, and of the oxide film is iron-rich. Also, Pouring and Shaking Recipes, D the cathode dark space. The latter some chromium is present in the Schlochet Nasato, S Pirker, T Lichte- Focusing on metal Perspectives from: attracts positive ions towards the surface oxide (Fig. 20). The meas- negger and C Kloss, as presented at cathode and generates sample ured thickness of the oxide film on Euro PM2015, Reims, France, EPMA, additive manufacturing • metal powder producers sputtering. The sputtering also sets 316L powders is 3 nm. The oxide film UK with powder metallurgy • toll providers free secondary electrons, which are is composed of iron, manganese, [3] Thermo-Optical-Measurement • end users accelerated in the electrical field chromium and silicon (Fig. 21). The Device for Sintering of PM Products (PM), this conference • equipment manufacturers towards the negative glow, where technique can reveal small elemental under Atmospheric Control, T Staab • R&D from academia and consortia they lose their energy through colli- enrichments at the top of the surface and A Diegeler, as presented at Euro will feature worldwide sions. During these collisions, the oxide film (Fig.22). The measured PM2015, Reims, France, EPMA, UK industry experts secondary electrons participate in area is 12.56 mm2 and the analysis [4] First Experiences on Topics will cover: excitation and ionisation processes time just a few minutes. Characterisation of Surface Oxide presenting the latest • materials and thus maintain the plasma. Therefore, it was concluded Films in Powder Particles by • applications The sputtering process depends that the method could become a GD-OES, I Heikkila C Eggertson M technology • technical barriers strongly on the sample material and powerful tool in defining averaged Randelius, S Caddeo-Johansson developments in this its surface properties, but, once the information on the chemistry and D Chasloglu, as presented at Euro • process economics atoms are sputtered, they move as thickness of surface films in powder PM2015, Reims, France, EPMA, UK fast-growing field. • new developments

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International Conference on Injection Molding of Metals, Ceramics and Carbides MARCH 7–9 • HOTEL IRVINE PM Titanium 2015: 6 IRVINE, CA Developments in the powder metallurgical Make plans to attend processing of titanium the only international metal and powder PM Titanium 2015, the third in the international series of conferences specifically focussed on the processing, consolidation and metallurgy of titanium, was held in Lüneburg, Germany, from August 31 to September 3, 2015. injection molding Dr David Whittaker reports for Powder Metallurgy Review on presentations that discussed the potential benefits of introducing higher levels of oxygen event of the year! or nitrogen into PM titanium materials, the use of Spark Plasma Sintering in the processing route and the development of a Hydrogen Sintering and Phase Transformation (HSPT) PM method. MIM2016 CONFERENCE (March 7–9) A two-day event featuring presentations, plant tour and a keynote luncheon • Innovative Processes & Materials • Dimensional Accuracy and Consistency The PM Titanium 2015 conference sessions on Additive Manufacturing Titanium materials with • Advances in Component Uniformity was held at Leuphana Univer- and Metal Injection Moulding. Articles light elements • Part Selection—Best Practices sity, Lüneburg, close to the city of discussing presentations from these • Leading Process Trends Hamburg, Germany, from August 31 sessions can be found in our sister Much attention is often given, in to September 3 2015. The event was publications Metal Additive Manufac- developing PM routes for titanium, • Tabletop Exhibition & Networking Reception with the latest in the series of inter- turing (Vol 1 No 3, Autumn/Fall 2015), to the control of interstitial elements Representatives from Many of the Leading national conferences focussed on and Powder Injection Moulding Inter- (such as oxygen, nitrogen, hydrogen Companies in the Field powder processing, consolidation and national (Vol 9 No 4, Winter 2015). and carbon) to the low levels speci- ...and Much More! metallurgy of titanium and follows successful conferences in Brisbane, Australia (2011) and Hamilton, New Optional One-Day Powder Injection Molding Zealand (2013). The conference Tutorial Precedes Conference (March 7) attracted over 130 delegates from 27 countries, and encouragingly for an Taught by Randall M. German, FAPMI area of technology where, to-date, the world-renowned PIM expert This conference is sponsored by the high level of R&D activity has not yet An ideal way to acquire a solid grounding in powder Metal Injection Molding Association, been matched by significant market injection molding technology in a short period of time a trade association of the penetration, several delegates from Metal Powder Industries Federation potential end-users were present, • Introduction to the manufacturing process representing the aerospace, biomed- • Definition of what is a viable PIM or MIM component ical and consumer products sectors. • Materials selection and expectations As well as discussing the powder • Review of the economic advantages of the process metallurgical processing of titanium, the technical programme also included a number of focussed Fig. 1 Participants at PM Titanium 2015 (Courtesy Dr Thomas Ebel)

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(a) N0 (b) N60 0.2990 0.4720 1400 1.0 Strain rate: 5.0x10-4/s 0.2985 0.4715 1200 N180 / nm 0.8 / nm N120 a 0.2980 0.4710 c

/ MPa Nitrogen 1000 N60 σ 0.2975 c-axis 0.4705 0.6 d=13.0 μm 50 μm d=8.2 μm 50 μm 800 0.2970 0.4700 600 0.4 (c) N120 (d) N180 0.2965 0.4695 Pure Ti (N0) 0.2960 0.4690 400 0.2 a-axis Oxygen 200

0.2955 0.4685 Nominal stress, Lattice parameter, Lattice parameter, 0.0 0.2950 0.4680 0 0 60 120 180 0.0 0.5 1.0 1.5 2.0 2.5 3.0 50 μm 50 μm 0 0.1 0.2 0.3 0.4 Nitrogen and oxygen content (mass%) d=7.0 μm d=6.3 μm Treatment time, t/mim Nitrogen content, cN (at.%) Nominal strain, ε

Fig. 2 Dependence of the nitrogen and oxygen contents Fig. 3 Optical microstructures and mean grain sizes of the Fig. 4 Lattice parameter changes in the a- and c-axes Fig. 5 Tensile stress-strain curves for extruded of SPS Ti powder materials on treatment time in the extruded Ti powder materials, using pure Ti powder with of extruded N0/60/120/180 Ti powder specimens, calcu- N0/60/120/180 pure Ti powder specimens at ambient gas-solid direct reaction [1] solute N atoms introduced via heat treatment for 0, 60, lated from each XRD profile [1] temperature [1] 120 and 180 mins in N2 gas atmosphere [1] exhibited almost the same structure imen was 974 MPa, a 122% increase Spark Plasma Sintering fied in standards for titanium wrought It was observed the yield strength a height of approximately 25 mm as the N0 (a) specimen with an equi- compared to the pure Ti 0.2%YS of products. In contrast to this preoc- increased in proportion with the using a spark plasma sintering axed α-Ti phase. However, the grain 439 MPa. Improvement in mechan- A further paper also involved cupation with their control to low oxygen content, but any decrease in (SPS) system at 1273 K for 30 min in size was refined with the increase of ical strength is generally accompa- Spark Plasma Sintering (SPS) levels, Katsuyoshi Kondoh, Takanori elongation was, surprisingly, very vacuum (~6 Pa). A pressure of 30 MPa nitrogen content. This is due to the nied by a loss of ductility. However, consolidation in the processing Mimoto, Junko Umeda and Hiashi small. The yield strength increment was applied in the SPS consolidation. solute drag effect of nitrogen, which the elongation decreased only from route. This paper, presented by Imai (Joining and Welding Research was in good agreement with calcula- In addition, a hot extrusion process prevents grain boundary migration. 29.6% to 21.7% in the presented Yongjun Su (Shanghai Jiao Tong Institute, Osaka University, Japan) tions, based on the Labusch model, was applied to the SPS billets, using XRD analysis allowed the study, indicating that the mechanical University, China) and co-authored presented a paper, which extolled taking into account an observed grain a hydraulic direct press machine. correlation of lattice parameters strength was remarkably improved by Yifeng Zheng and Delian Zhang the potential benefits of operating refinement effect. Extruded pure Ti The nitrogen and oxygen contents with nitrogen content, as shown with little sacrifice in ductility with (also Shanghai Jiao Tong, University) and Fantao Kong (Harbin Institute at much higher levels of oxygen or powder material with 1.5 wt% TiO2 of each SPS Ti powder sample are in Fig. 4. The interstitial solution the 0.72 mass% nitrogen addition. nitrogen and developing process had a yield strength of 1025 MPa and presented in Fig. 2. The nitrogen of nitrogen atoms in the α-Ti hcp It was concluded that the of Technology, China), focussed on content increased as the treatment structure caused a considerable extruded Ti-N materials were chiefly the microstructures and mechanical time of the process increased. The expansion on the c-axis, while the strengthened by a solid solution properties of a Ti-43Al-5V-4Nb-Y “...yield strength increased in powder treated for 180 min (denoted a-axis was much less affected by hardening mechanism by nitrogen alloy processed by SPS. proportion with the oxygen content, as N180 powder) showed the highest nitrogen content. On the basis of (as illustrated in Fig. 4). In addition, TiAl alloys are light-weight nitrogen content of 0.90 mass% in these XRD results, it was concluded a second strengthening effect structural materials, used for high but any decrease in elongation was, this study, which was a remarkably that the nitrogen atoms, introduced involved grain refinement, created by temperature applications such as surprisingly, very small.” high nitrogen level compared to those by the gas-solid direct process, were solute drag (as illustrated in Fig. 3) aero-engine turbine blades, due reported in previous studies (up to homogeneously dissolved in the α-Ti and this was chiefly responsible for to their low density and excellent approximately 0.4 mass%). On the matrix. the observed relatively low level of properties, including relatively routes to take advantage of the solid an elongation of 24.8%. Also, a post- other hand, the oxygen content in Room temperature tensile testing reduction in ductility. high yield strength at elevated solution strengthening benefits avail- sintering heat treatment was found all of the SPS samples was almost was carried out in order to assess able from these alloying elements. to be effective in creating a further the same (approximately 0.2 mass%, the mechanical behaviour of the The authors identified two effec- improvement in the balance between equal to that of the pure Ti starting extruded N0/60/120/180 speci- 3000 -Ti tive process routes for the deliberate strength and ductility, because of the powder). It was therefore concluded mens and the stress-strain curves -Al 2500 introduction of oxygen or nitrogen into complete dissolution of oxygen atoms that the nitrogen content of treated obtained are shown in Fig. 5. Tensile -TiAl3 PM titanium materials: direct reaction into HCP-Ti. Ti powders and their consolidated strength was gradually increased 2000 between titanium powder and the The reported introduction of samples via the gas-solid direct reac- when the nitrogen content was respective gases and the inclusion of nitrogen involved the direction reaction process is simply controlled by raised from 0.52 mass% (in N60) to 1500 TiO2 or TiN in elemental powder mixes. tion of pure Ti powders in nitrogen changing the treatment time and not 0.90 mass% (N180) and offered an For example, sintered and extruded Ti gas. Nitrogen can dissolve in Ti to by varying oxygen content. outstanding combination of excellent Intensity (cps) 1000 samples with oxygen in solid solution form an interstitial solid solution in Optical microstructures with strength and sufficient ductility with were prepared by using an elemental large amounts (19 at% in α-Ti). In this average grain sizes (denoted as d in the nitrogen addition content of 0.74 500

mix of pure Ti powder and TiO2 parti- study, the content of nitrogen in solid the figure) of the extruded samples mass% (N120). The ultimate tensile 0 cles. With an increase in TiO2 addition, solution in Ti powder was controlled N0 (pure Ti starting powder), N60, strength (UTS) of the N120 specimen X-ray diffraction (XRD) studies showed by changing the heat treatment time N120 and N180 are shown in Fig. 3. was 1120 MPa, an 82% increase over 20 40 60 80 100 2theta (deg.) that the lattice constant in the c-axis in a N2 gas flow (gas-solid direct It can be seen from the N60 (b), the 617 MPa obtained from extruded of HCP-Ti(α) increased in proportion reaction). The treated powders were N120 (c) and N180 (d) samples that pure Ti (N0 with nitrogen content of with the increase in oxygen atoms in consolidated into columnar billets specimens with nitrogen addition via 0.02 mass%). Moreover, the 0.2% Fig. 6 XRD pattern of the Ti-43Al-5V-4Nb-Y alloy sample sintered at 650°C solid solution. having a diameter of 42 mm and the gas-solid direct reaction process yield strength (YS) of the N120 spec- under 20 MPa pressure and with a holding time of 5 min [2]

temperatures, good creep resistance, and excellent a) oxidation/corrosion resistance. Several methods have 1200 600 60000 -TiAl Heat treatment -Ti been developed for fabricating TiAl alloys such as 500 -TiAl 1000 -Ti3Al 50000 3 vacuum arc remelting (VAR), casting and hot working. -TiAl One of the main problems associated with ingot 400 -Ti Al 800 SPS 40000 3 metallurgy methods is the scatter in the mechanical -B2 properties of materials, due to compositional 600 300 30000 inhomogeneity. Powder Metallurgy is an alternative 200

400 Stress (MPa) 20000 processing route that can provide better chemical Intensity (cps) Intensity (cps) homogeneity and is able to form near net shape 200 100 10000 products, thus minimising the requirements for post processing machining. Also, PM offers an opportunity to 0 0 0 20 40 60 80 100 0.0 0.2 0.4 0.6 0.8 1.0 1.2 20 40 60 80 100 prepare fine-grained components together with better 2theta (deg.) Strain (%) 2theta (deg.) control over chemical and phase compositions. Among the various PM consolidation processes, Fig. 9 XRD pattern of the Ti-43Al-5V-4Nb-Y alloy sample Fig. 10 Room temperature stress-strain curves of the Spark Plasma Sintering is a promising technique, which after heat treatment [2] samples sintered at 1300°C for 5 min and heat treated at b) involves sintering powders by simultaneously applying 1300°C for 1 hour [2] 80000 -TiAl a uniaxial pressure and current pulses of high intensity. 70000 + TiAl → Ti Al + TiAl + TiAl and Ti Al the sample after heat treatment, the -Ti Al Some published studies have focussed on the SPS 3 3 2 3 Hydrogen Sintering 3 + TiAl + TiAl → TiAl. Because the compact consists of TiAl and Ti Al 60000 -B2 of pre-alloyed TiAl based alloy powders, obtained by 2 3 sintering temperature is low and the phases and the B2 phase has disap- The final paper reviewed in this 50000 atomisation or mechanical alloying, and have shown that holding time is short, these reactions peared. report was presented by Zak Fang it is possible to obtain very fine microstructures. Alloys 40000 are still incomplete. Furthermore, Fig. 10 shows the room tempera- (University of Utah, USA), was processed by this route have high strength, but their 30000 there exists a small amount of B2 ture engineering stress-strain curves co-authored by Matt Dunstan, James

Intensity (cps) ductility is still limited. phase in the microstructure. The B2 for the samples sintered at 1300°C Paramore and Mark Koopman (also 20000 The presented work has therefore assessed the SPS phase is soft at elevated tempera- for 5 minutes with and without University of Utah) and described 10000 processing of a Ti-43Al-5V-4Nb-Y alloy from a mix of tures, due to its bcc structure, and subsequent heat treatment at 1300°C the development of the Hydrogen 0 elemental powders. The SPS processing temperature can be deformed more easily than for one hour. Sintering and Phase Transforma- 20 40 60 80 100 was varied in the range from 650°C to 1300°C. Fig. 6 Ti Al and TiAl. When the sintering The sample sintered at 1300°C tion (HSPT) PM method, capable of 2theta (deg.) shows the XRD pattern of the sample which was sintered 3 temperature is 1250 or 1300°C, the for 5 min had a tensile yield strength delivering wrought-like microstruc- at 650°C under a pressure of 20 MPa and with a holding microstructures of the samples are of 396 MPa, a UTS of 461 MPa and ture and mechanical properties in a time of 5 min. The clear diffraction peaks of the XRD c) 60000 composed mainly of Ti Al and TiAl an elongation to fracture of 0.7%. Ti-6Al-4V alloy. -TiAl pattern confirm that, when the sintering temperature is 3 and a small amount of B2 phase The heat treatment at 1300°C for Powder Metallurgy methods have 50000 -Ti3Al lower than the melting point of aluminium (660°C), the (Figs. 7b and 7c). one hour led to an improvement in long been investigated as a means -B2 sample consists of Ti, Al and Al Ti phase, suggesting that 40000 3 Fig. 8 shows the microstructures room temperature yield strength to of reducing the cost of titanium alloy an interfacial diffusion reaction occurs between solid of samples sintered at 1150, 1200, 527 MPa and a slight improvement production by utilising their near- Ti and Al below the melting point of aluminium. This 30000 1250 and 1300°C, under a pressure of elongation to fracture to 0.8%. net-shape capabilities. However, reaction can be described as: Ti + Al → Al Ti. 3 of 50 MPa and with a holding time of This can be attributed to the more traditional PM methods produce 20000 Intensity (cps) Fig. 7 shows the XRD patterns of the samples fabri- 5 min. When the SPS temperature complete dissolution of Nb-rich and poor mechanical properties resulting cated at 1200, 1250 and 1300°C, respectively, under a 10000 was 1200°C, niobium rich particles V-rich particles by the heat treat- from residual porosity, high inter- pressure of 50 MPa and with a holding time of 5 min. (Point D) and pores were observed. ment, which increases the content of stitial concentrations and a coarse 0 With an SPS temperature of 1200°C, the sample consists When the SPS temperature was Nb and V in the α2/ɣ lamellae and the as-sintered microstructure. There- 20 40 60 80 100 of Ti Al, TiAl, TiAl , B2 phases and remnant Ti phase 2theta (deg.) 3 3 1250 or 1300°C, a duplex structure disappearance of the B2 phase (as fore, energy-intensive processes, (Fig. 7 a). It has been reported that when the tempera- was obtained, but Nb-rich areas still confirmed by XRD analysis). such as pre-alloying the powder, ture is higher than the melting point of aluminium, an existed in the microstructure as a Fig. 7 XRD patterns of the Ti-43Al-5V-4Nb-Y alloy sintered exothermic reaction exists between solid Ti and liquid result of incomplete dissolution. In at temperatures of: a) 1200°C; b) 1250°C; c) 1300°C [2] Al, and that, then, the reactions will occur as follows: Ti addition, many small white grains were distributed in crystal and grain Controlled hydrogen Vacuum Vacuum boundaries (Figs. 8c and 8d). The β-Ti sintering β-Ti sintering results of EDS analyses showed that (Densification) Dehydrogenation (Densification) these small white dots were Y2O3 particles (Point H). Samples sintered at 1300°C for 5 Temperature Temperature min were also subjected to post- sintering heat treatments. Fig. 9 Time Time shows the XRD pattern of the sample after heat treatment at 1300°C for (a) HSPT process profile (b) Vacuum sintering profile Fig. 8 SEM backscattered electron images of the Ti-43Al-5V-4Nb-Y alloy samples sintered at different temperatures: a) one hour. The clear diffraction peaks 1150°C; b) 1200°C; c) 1250°C; d) 1300°C [2] of the XRD pattern suggest that, in Fig. 11 Sintering profiles of the a) HSPT process, and b) vacuum sintering [3]

pressure assisted sintering and incorporates densification and process is the possibility of excess at 750°C under a rough vacuum a) b) thermomechanical processing (TMP), dehydrogenation in one step. hydrogen content in the as-sintered (10-1 Pa) using a rotary vane pump. have been used to reduce porosity Figs. 12a and 12b compare material, as hydrogen content After the prescribed dehydrogenation and refine the microstructure to the microstructures of Ti-6Al-4V has a strong influence on fracture time, the furnace was backfilled

produce mechanical properties that processed via TiH2 vacuum sintering toughness and fatigue behaviour with ultra-high purity argon gas. The can compete with wrought processed and HSPT respectively. A distinct of Ti-6Al-4V. As shown in Fig. 11, samples were then removed from Ti alloys. However, these processes difference in the microstructures the last step of the process is to the furnace and quenched in water to eliminate the economic benefit of is observed, with the HSPT process dehydrogenate to remove hydrogen prevent the hydrogen concentration

PM. TiH2 sintering in vacuum has producing an ultra-fine lamellar been extensively studied and has structure in the as-sintered state. been shown to increase densifica- The microstructural refinement that “The ultra-fine microstructure that is 30 μm 5 μm tion kinetics and reduce interstitial is achieved in the HSPT process formed in the as-sintered state gives Fig. 12 SEM micrographs of a) TiH2 vacuum sintered Ti-6Al-4V, and b) HSPT contamination. However, vacuum results from hydrogen acting as a rise to excellent mechanical properties processed Ti-6Al-4V [3] sintering of TiH2 produces a coarse strong β stabiliser and this, in turn, lamellar microstructure similar to creates a pseudo-metastable β for a mixed elemental PM alloy” traditional Ti PM sintering. There- alloy. On cooling from the sintering a) b) fore, the development of the HSPT temperature, the nucleation and process has had the principal aim of growth of the α phase is suppressed to a satisfactory level. The ASTM profile equilibrating during cooling. producing fully dense titanium alloys and the α phase precipitates as α and B348 standard requires that the Dehydrogenation times were varied

with a refined microstructure without α2 in a fashion similar to β Ti alloys. hydrogen content in Ti-6Al-4V should from as little as 30 minutes to 24 utilising energy-intensive powder The ultra-fine microstructure that be less than 150 ppm. Another hours, depending on the sample size. preparation, exotic sintering methods is formed in the as-sintered state issue is therefore the kinetics of Sample sizes ranged from 9 mm or TMP. gives rise to excellent mechanical dehydrogenation, which may have a to 40 mm diameter cylinders. After HSPT has therefore been devel- properties for a mixed elemental PM significant impact on the practicality dehydrogenation, each sample was oped as a low cost, mixed elemental, alloy that compete with properties and economics of the technology. sectioned and chemical analysis was die press and sinter Powder Metal- achieved from wrought processing. In the presented paper, therefore, a then performed to measure oxygen, 15 μm 15 μm lurgy process. To produce the desired Furthermore, the ultra-fine nature series of systematic experiments was nitrogen and hydrogen concentrations. alloy composition, powder mixes are of the microstructure allows for conducted to study the dependence For the concentration profile samples,

Fig. 13 Optical micrographs of a) bimodal HSPT and b) globular HSPT [3] prepared from Ti, TiH2 and/or master successful heat treatment to produce of the kinetics on dehydrogenation a 30 mm section was removed from alloy powders before compaction and wrought-like microstructures time and geometry in the last step of the centre, with radial slices being sintering. During HSPT, the compacts without TMP. This ability is unique the HSPT process. Both experimental sectioned for hydrogen analysis. Condition UTS [MPa] σy,0.2%[MPa] Elongation [%] are sintered in dynamically controlled to the HSPT process and cannot be data and an empirical model for The hydrogen concentration partial pressures of hydrogen and achieved by vacuum sintering due to dehydrogenation were presented. profiles for the large samples HSPT[*] then subjected to a vacuum anneal the coarse lamellar grains. Figs.13a In these experiments, TiH2 powder dehydrogenated for various times, As-sintered 994-1024 930-974 13.8-17.8 (dehydrogenation). and b show the microstructures was cold isostatically pressed, to from 1.25 to 12 hours, are shown in Fig. 11 compares the sintering of HSPT samples that have been form cylindrical samples of varying Fig. 14. As the dehydrogenation time is Bi-modal 1070-1076 981 10.7-11.9 profiles of the HSPT process and heat treated using traditional heat size. These samples were then increased, a corresponding decrease traditional vacuum sintering. The treatment methods to produce sintered using the HSPT process in hydrogen concentration and a Globular 949-952 872-881 17.6-19.2 HSPT process comprises three main a bi-modal and a globularised described in Fig. 11. Each sample flattening of the profile is observed. Vacuum steps. During the first two steps, microstructure. was individually dehydrogenated The profiles flatten at roughly 100 a dynamically controlled hydrogen Table 1 compares the ASTM As-sintered[**] 982 859 12 partial pressure is utilised to control standard for quasi-static mechanical 4500 the hydrogen concentration within the properties of Ti-6Al-4V with those ASTM 4000 alloy. In the first step, densification achieved by means of TiH2 vacuum B348 (Grade 5 Ti-6Al-4V )[***] 895 828 10.0 is achieved at a temperature above sintering and HSPT sintering with 3500 the β-transus. During this first step, as-sintered, bi-modal and globular 3000 1.25 hr Increasing time 2.5 hr Table 1- Mechanical property comparison of HSPT, vacuum sintering, and the presence of dissolved hydrogen microstructures. From these data 2500 ASTM standard B348 for Grade 5 Ti-6Al-4V [3] significantly improves densification and the micrographs in Fig. 13, 3.75 hr 2000 kinetics, resulting in nearly full it can be seen that HSPT has the 5 hr * J. D. Paramore, Z. Z. Fang, P. Sun, M. Koopman, K. S. R. Chandran, and M. densification. The material is then capability to tailor the microstructure 1500 7.5 hr Dunstan, “A powder metallurgy method for manufacturing Ti-6Al-4V with wrought- 10 hr cooled below the β-transus to and produce mechanical properties 1000 like microstructures and mechanical properties via hydrogen sintering and phase 12 hr

refine the microstructure via phase competitive to wrought processing Hydrogen Concentration [ppm] transformation ( HSPT ),” Scr. Mater., vol. 107, pp. 103–106, 2015 500 transformations in the Ti(alloy)-H while avoiding the cost of TMP. ** Z. Z. Fang, P. Sun, and H. Wang, “Hydrogen Sintering of Titanium to Produce High 0 system. The final step is a vacuum Additionally, dynamic testing of 0 1 2 3 4 5 6 7 8 9 10 Density Fine Grain Titanium Alloys,” Adv. Eng. Mater., vol. 14, no. 6, pp. 383–387, Jun. anneal, or dehydrogenation, at a HSPT-produced Ti-6Al-4V has Radius [mm] 2012. temperature below the β-transus demonstrated fatigue strength on a *** “ASTM Standard B348-10 Standard Specification for Titanium and Titanium Alloy to remove all residual hydrogen. par with wrought Ti-6Al-4V. Fig. 14 Hydrogen concentration profiles of the large samples for various dehy- Bars and Billets,” West Conshohocken: ASTM International, 2010 In comparison, vacuum sintering A significant issue in the HSPT drogenation times [3]

62 Powder Metallurgy Review Winter 2015 © 2015 Inovar Communications Ltd © 2015 Inovar Communications Ltd Winter 2015 Powder Metallurgy Review 63 PM Titanium 2015 | contents page | news | events | advertisers’ index | email | owder etallurgy SHANGHAI As a final note, it was emphasised 4500 that, in the experiments discussed in APRIL 27-29 the paper, a rough vacuum (10-1 Pa) 4000 was used to dehydrogenate samples. X Large (40 mm) This absolute pressure created a 3500 Large (22 mm) hydrogen partial pressure corresponding to a minimum (equilibrium) Medium (13 mm) 3000 hydrogen concentration around 100 Small (9 mm) PM CHINA 2016 ppm hydrogen. Whist this value is still 2500 within the specifications of the ASTM B348 standard for titanium alloys, further experiments have shown that, China’s largest PM & MIM exhibition H (ppm) 2000 on using a higher speed pump such 1500 as a diffusion or turbo molecular pump, hydrogen concentrations below 10 ppm can be produced. 1000

500 References [1] State of The Art PM Ti Materials 0 with Ubiquitous Light Elements, K 0 5 10 15 20 25 30 Kondoh, T Mimoto, J Umeda and H Dehy Time (hr) Imai, as presented at PM Titanium 2015, August 31 to September 3, 2015 Fig.15 Hydrogen concentration at the centre of samples for various samples Lüneburg, Germany. sizes and dehydrogenation times [3] [2] Microsturctures and Mechanical ppm. Therefore, it was considered performed to include the hydrogen Properties of Ti-43Al-5V-4Nb-Y likely that this was the equilibrium concentration, the natural logarithm Alloy Consolidated by Spark Plasma hydrogen concentration within the of the dehydrogenation time and the Sintering, Yongjun Su, Yifeng Zheng, sample for the hydrogen partial sample diameter. A confidence level Delian Zhang and Fantao Kong, as pressure generated by the roughing of 95% was used. The results of this presented at PM Titanium 2015, pump. In order to have a thorough regression analysis are given in the August 31 to September 3, 2015 understanding of the kinetics of following equation: Lüneburg, Germany. dehydrogenation, an attempt to [3] Powder Metallurgy Ti-6Al-4V Alloy fit a model to the concentration C = 1366.94 – 1345.39ln(t) + 91.91d H with Wrought-like Microstructure and profile was made using a solution Mechanical Properties by Hydrogen | Materials | Equipment | Products | Solutions | of Fick’s Second Law. However, this Where C is the hydrogen concen- H Sintering, Z Fang, M Dunstan, J Para- model relied heavily on the diffusion tration at the sample centre in ppm, more and M Koopman, as presented coefficient of hydrogen in titanium, t is the dehydrogenation time in at PM Titanium 2015, August 31 which was found to vary depending hours and d is the sample diameter to September 3, 2015 Lüneburg, on the degree of dehydrogenation due in mms. This equation is particularly Germany. to phase transformations occurring useful in an industrial setting, where The leading trade fair for Powder Metallurgy in China in the Ti-H system, and, therefore, Ti parts are not uniform in shape. an empirical equation relating Unlike the theoretical model, which is Author The most effective platform to display your competitive edge the hydrogen concentration to the only applicable to cylindrical bars, the Dr David Whittaker dehydrogenation time and overall equation provides information on the 231 Coalway Road sample diameter was developed. time needed to dehydrogenate for the Wolverhampton our gateway to the Chinese market To develop this empirical largest diffusion length. This makes WV3 7NG, UK equation, the centre concentrations it applicable to irregular shapes. Tel: +44 (0)1902 338498 PIM symposiom and PM industry forum of four sample sizes were measured The equation is also helpful in the Email: [email protected] for varying dehydrogenation times. determination of the dehydrogenation The results are shown in Fig. 15. cost. Dehydrogenation time can vary PM Titanium 2015 From this figure, a logarithmic depending on the sample size and the Conference Proceedings relationship between hydrogen ability to determine the time required The full proceedings of the confer- concentration and dehydrogenation to dehydrogenate a component Shanghai Everright Convention Exhiition Center time is observed. To determine allows a cost estimation of the HSPT ence will be available in early 2016. the empirical equation, a process to be more easily tailored to For further information contact PM CHINA 2016 Organiing Committee multiple regression analysis was a specific component. Thomas Ebel: [email protected] Tel: 86-400 077 8909 Fax: 86-21-23025505 Contact: Maggie Song Email: pmexpochina163.com 64 Powder Metallurgy Review Winter 2015 © 2015 Inovar Communications Ltd .cn-pmexpo.com

Japan’s automotive industry drives advances in Powder Metallurgy technology

The winners of the Japan Powder Metallurgy Association’s (JPMA) 2015 Powder Metallurgy Awards showcase the continuing developments being made to further expand the range of applications for Powder Metallurgy. The demands of the automotive industry for ever more efficient engines continues to require improved mechanical properties and flexibility of design, both of which PM can offer. The winning components in this years awards recognise innovations in new materials, manufacturing processes and component design, not just in the automotive sector, but in a number of other important industries.

Development prize: This development improved the highly wear-resistant material on New design layer boundary angle to 45 degrees, the valve seat without waste because which is parallel to the valve- wear progresses parallel to the Enhanced cost effectiveness impacting surface angle. The amount valve-impacting surface. Moreover, through the reduction of wear of expensive material is therefore the valve seat needs to have heat resistant material on the valve seat reduced. Furthermore, a drastic cost conduction performance since the Fine Sinter Co. Ltd. received an reduction is achieved by locating the interior temperature of the engine award for a modified design concept for valve seats (Fig. 1). This valve seat provided an improvement in Now available as a FREE PDF download cost effectiveness by minimising the amount of highly wear resistant material used through the reviewing of the layer boundary angle. The PIM International is the only publication dedicated • Available as a FREE PDF download from valve seat has expensive, highly to serving the global PIM industry, comprising www.pim-international.com/magazine wear-resistant material (seat mate- the metal (MIM), ceramic (CIM) and carbide • Exclusive industry news rial) on the seat surface where the valve impacts, because impacting injection moulding sectors. Don’t miss the latest • Specially commissioned features the valve wears the seat. Therefore, commercial and technological developments from • Company visits in order to improve cost effectiveness, the developed valve seat has this dynamic high-growth industry..... • Conference reports and much more two layers with a cheaper material (base material) on the cylinder head side because wear resistance is not required on this part of the compo- Print subscriptions are also avialable for £135. For more information visit www.pim-international.com/subscribe Fig. 1 These valve seats offer cost savings by minimising the amount of wear nent. resistant material used (Courtesy JPMA)

The customer was initially considering the full- machining of a stone bearing, such as Ruby and Sapphire. However, as a result of this development, Porite were able to enter this new market.

A set of sintered joints for the motor used in a valve lift actuator Diamet Corporation received an award for the development of a set of sintered joints for the motor used in the valve lift actuator of an SOHC engine (Fig. 4). One of the components has projections and the other has grooves. In combining the projections and grooves, the width between the projections is a critical issue. The compaction tool and the compaction conditions were optimised to minimise the distortion caused by spring- Fig. 4 Sintered joints for the motor used in a valve lift back. The sintering method and conditions were also actuator (Courtesy JPMA) Fig. 2 A soft magnetic composite core for a rectan- Fig. 3 Sintered bearing for a linear vibration actuator used in a optimised to improve the scatter of dimensional changes. gular ignition coil (Courtesy JPMA) wearable device (Courtesy JPMA) As a result, the company has succeeded in developing the set of sintered joints for the motor used in the valve is becoming higher with the trend is being more widely adopted, due Development of a bearing for a lift actuator and the sizing process has been eliminated. towards higher efficiency engines, to their improvement of thermal linear vibration actuator to be used These developments have contributed to the practical use but the use of highly wear resistant efficiency and suppression of in a wearable device of the new mechanism, improving fuel economy and envi- material as the seat material nitrous oxide formation. However, Porite Corporation received an award ronmental performance and contributing to the potential reduces heat conductivity because of the applications for these tech- for the development of a sintered for downsizing. the hard layer that includes carbide. nologies are limited because their bearing which is used for the linear Decreasing the proportion of utilisation can degrade ignitable vibration actuator in a wearable Development prize: New materials highly wear resistant material stability. device (Fig. 3). The vibration motor improves total heat conductivity and Therefore, there is a demand for has been mounted on the Pocket An austenitic high heat and wear resistant sintered provides a heat reduction effect. the development of an ignition coil Bell since around 1990 and its use material for a turbocharger application This effect contributes to the control with superior ignitable stability. The has increased in number with the Hitachi Chemical Co. Ltd. received an award for the of knocking that is caused by the key points in this development were: spread of the use of the mobile development of an austenitic sintered material with higher temperature of the engine. In (1) Improvement of the magnetic telephone. Mobile telephones in the excellent heat and wear resistance and for use in the Fig. 5 Material with excellent heat and wear resistance for addition, machinability of the outer saturation-resistance that is the world market are transforming into valve bushing in a turbocharger (Fig. 5). The usage of use in turbocharger valve bushings (Courtesy JPMA) diameter is improved because of the characteristic of soft magnetic smart phones from feature phones. turbocharger in vehicles has been increasing recently. reduction of the area of the highly composites. Also, small, high performance and Turbochargers have conventionally been used in diesel wear resistant material on the outer health-conscious wearable devices (2) Improvement of volumetric engine vehicles, but their usage has now also been diameter, which requires heavy with vibration features have entered efficiency. This was achieved via a expanding in gasoline engines. Since the exhaust gas machining. the market. These wearable devices circular re-design of the cross- temperatures in gasoline engines are higher than those are thin and curved so that a thin, sectional shape taking advantage in diesel engines, austenitic materials tend to be used as Development of a soft magnetic flat-shape linear actuator is required, of the shape flexibility of the soft turbocharger parts because of their superior heat resist- composite core for high-power rather than the cylinder and coin type magnetic composite core. This ance. To respond to these requirements a new austenitic output and rectangular-shaped actuator which has been the main- type of circular design is difficult sintered material with higher wear resistance has been ignition coil stream to date. to achieve using conventional developed. Sumitomo Electric Industries Ltd. The company has developed a electromagnetic steel sheet. The technical success of this material rests on the received an award for the develop- sintered bearing, which has satis- condition of the dispersion of carbides, introduced for (3) Achievement of high produc- ment of a soft magnetic composite fied the characteristics for a linear wear resistance improvement. On increasing the amount tivity and cost competitiveness core for a rectangular-shaped vibration actuator (vibration char- of carbide through an increase in the carbon content, through an automated process Fig. 6 This ferrous bearing material has high permeability ignition coil, possessing superior acteristic, low noise, shock resist- wear resistance can be improved but deterioration of from compacting to packing, and oil content (Courtesy JPMA) ignitable stability resulting in high ance). This product required different oxidation resistance also occurs because of the lower which is unprecedented in the ignition energy output (Fig. 2). Due to characteristics from the rotating Cr content in the matrix. On the other hand, it was Ferrous sintered bearing material with high perme- manufacture of sintered parts. increasing environmental concerns vibration motor. The radius shape found that finer carbide could improve wear resistance ability and oil content and a consequent significant focus Through these improvements, on the inner diameter was formed without oxidation resistance deterioration. Therefore, this Hitachi Chemical Co. Ltd. received an award for the on fuel economy in the automotive the company has succeeded by special tooling in order to remove technology has been applied in the developed material. development of a ferrous bearing material that has highly market, there is a growing demand in developing a soft magnetic a fine burr. Low noise material with As a result, an austenitic sintered material, which was permeability and oil content and that has already been for engines with higher thermal composite core for the rectangular- a high oil film strength, provided by superior in heat and wear resistance to the products of used in printer head driving motors (Fig. 6). It is suitable efficiency and lower emissions. shaped ignition coil possessing fine porosity and the use of a high alternative processes, was developed. The developed for applications, which are difficult for oil impregnated The use of technologies such as superior ignitable stability and viscosity oil specialised for linear material has proved to be successful in penetrating the sintered bearings to generate an oil film effect through a direct-injection lean burn (thin fuel) resulting in high ignition energy sliding motion, were the keys to market for turbocharger bushings for gasoline engines. pumping action. and EGR (exhaust gas recirculation) output. success in this development.

bearing material, which can be used production of compacts with no in difficult conditions for achieving an galling. Furthermore, because dead oil film effect, was developed and was space in the lubricant coating region, successfully adopted in printer head non-uniform lubricant coating due to driving motors. concentration of the electrical field at convex shapes and other problems associated with the spray method do Development prize: Process not occur, the developed method can Development of a high-density respond easily to lightening holes and complex shapes. sprocket for automobile engines made by die wall lubrication and As a result of this development, compaction at room temperature industrial production of high density sprockets with higher productivity in Hitachi Chemicals Co. Ltd, received comparison with the tooth flank form a prize for this development, which rolling method and the conventional relates to die wall lubrication in warm die wall lubrication compacting compaction and which makes it method was successfully demon- possible to achieve high density strated. Fig. 7 Die wall lubrication in compaction makes it possible to achieve high without additional manufacturing density without additional manufacturing processes (Courtesy JPMA) processes (Fig. 7). The developed technology realised products with densities of 7.5 Mg/m3 and higher Effort prize Fig. 9 This partially alloyed bronze powder with high compactibility achieves a shape complexity, whilst eliminating Development of planetary carrier homogenized sintered structure (Courtesy JPMA) the compacting speed rate-deter- for E-4WD applied with sinter mining step in the lubricant coating brazing technology columns. This has enabled the design because a large amount of liquid process. Sumitomo Electric Industries Ltd, of a carrier that can withstand high phase tin appears during sintering. In lubricant coating using the received a prize for the develop- torque generated during high speed Also, the gas inside sintering conventional spray method, reduc- ment of a sinter-bonded planetary driving with sinter-bonding of the compacts has difficulty in escaping tion of compacting speed and the carrier, in which individual columns columns despite the weight saving smoothly, especially in the case of ability to respond to the incorporation are joined to the main body of the features such as miniaturisation. the compacts with higher densities. of lightening holes were challenges. carrier to overcome strength limita- This development has led to On the other hand, alloyed powders To solve these problems, a new die tions (Fig. 8). A great focus has implementation of a sinter-bonded do not cause demixing and segrega- wall lubrication compacting method been placed recently on miniaturi- carrier in a high torque application tion and achieve homogenized high was developed, in which coating of sation and weight savings in order which was conventionally difficult density sintered compacts because the lubricant is completed in the die to improve fuel efficiency, but the to achieve. The product has been the liquid phase does not appear in operation cycle from ejection from consequent adverse effect on compo- adopted in a 4WD system used in the sintering process. However, their the compacting process to return for nents is that they are subjected to hybrid vehicles. compactibility is so poor that it is filling, thereby achieving the same higher stress. difficult to produce complex shaped compacting speed as in conven- The developed product is used in a Partially alloyed bronze powder parts using them. Fig. 8 Sinter-bonded planetary carrier, in which individual columns are joined tional compacting. In addition, in the planetary gear mechanism and this with high compactibility suitable for In order to solve these problems, to the main body of the carrier (Courtesy JPMA) spray method, the die is generally was designed to possess a large high sintered density electrolytic copper powder has heated for the purposes of increasing reduction ratio especially in large Fukuda Metal Foil & Powder Co. Ltd been used as a matrix to improve Because of both a short operating to be the solution and these can the adhesion between the die wall planetary gears in order to meet a received a prize for the development the compactibility and bronze alloy time and a reversible rotation, the be achieved by lowering density. surface and a solid lubricant, or requirement of weight saving and of a partially alloyed bronze powder powder with a high melting point has printer head driving motor is one However, lower density has a drying the solution of a solid-liquid also to transfer rotation from motor with high compactibility to enable the also been used as a tin source to of the most difficult applications, deleterious influence on productivity mixed lubricant. The developed to rear wheel. Therefore, stress prevention of demixing and segre- avoid the formation of a liquid phase. in which to obtain an oil film effect. through poor green strength. Addi- method makes it possible to obtain reduction is one of the key factors in gation and achieve a homogenized These powders are diffusion-bonded Copper materials, which have high tionally, a material was required that the desired product properties under the planetary carrier design. sintered structure (Fig. 9). to each other in order to suppress self-lubricity, were thought to be had similar self-lubricity to a copper a cold condition (room temperature) In a conventional sinter-bonded Either a mixture of copper and tin demixing and segregation. During superior for such applications, but material for product reliability. without heating the die. carrier, the design of R feature is powders blended at the prescribed the diffusion bonding, a heat treat- the development of a ferrous material The developed material achieved Lubricating oil, which is supplied at the base of the column forming ratio, or alloyed powders produced by ment is carried out at a relatively low was pursued in order to offer a less five times higher permeability than through the interior of the die, is hollow shapes but only on one side, the atomisation method, have been temperature to suppress inter-diffu- expensive bearing for the application. a conventional ferrous material, coated uniformly on the die inner wall thus restricting its use to low torque generally used as a raw material sion as much as possible. The target Increasing the oil supply ability which has 80% density ratio. The surface or side surface during die units. Therefore, the company’s for bronze sintered parts. However, properties have thus been achieved of a bearing material is important green strength was maintained at operation from the ejection posi- novel proposal was to incorporate the mixed powders cause demixing and the powder has been success- in achieving an oil film effect under a level equal to that of the convention to return for filling. The coated the R feature design on both sides and segregation while they are fully commercialised. the usage conditions referred to tional material by using both sponge lubricating oil functions as a release of columns thus relieving the high flowing and a decrease in density www.jpma.gr.jp above. Therefore, increasing perme- iron powder and a new compac- agent when the green compact is stress from the two sides of the of sintered compacts also occurs ability and oil content were deemed tion lubricant. As a result, a ferrous ejected after compacting and enables

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A robust helical PM gear compaction solution with 17% gear weight reduction in comparison to the wrought steel gear. This is one of our latest achievements at the Höganäs PoP Centre. Here, we are combining our latest metal powders and lubricant innovations with state-of-the-art multilevel press and helical gear tooling capability.

We have used a novel design-for-PM approach to develop, prototype and test drive all gears in a design optimized popular European 6-speed passenger car transmission. The result: smart PM gear designs can help OEMs reduce weight and inertia in their transmissions. Additional advantages include cost saving opportunities through a shortened gear manufacturing process chain and lowered investment costs when setting up a new gearbox plant.

Join Höganäs and the Powder Metal Gearbox Initiative at CTI Symposium and Transmission Expo December 8-10 in Berlin, Germany Watch compaction of Stand K 01 advanced helical gear

Inspire industry to make more with less. www.hoganas.com/pmc