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(PM) for Beginners Petitive and Special Exclusive Today and the a People Lurgy Tant This Good Many Key Designs Powder Metallurgy (PM) for Beginners An Introductory Lecture Beginners EuroPM2017, Milan, October 2, 2017, 14:00-15:30 This short lecture covers impor- tant key topics of Powder Metal- lurgy. It has the target to give people with no PM background Dr. Volker Arnhold a good basic understanding of Powder Metallurgy Solutions the many materials, processes and applications PM is offering Wuppertal, Germany today. The prime drivers are exclusive materials (captive), special alloys, microstructures and designs (unique) and com- petitive reasons (economic). Powder Metallurgy Powder (PM) for 1 Dr. Volker Arnhold Powder Metallurgy Solutions Wuppertal, Germany Beginners ([email protected]) • Born 1949 in Wuppertal, Germany • Diploma Physics + PhD at WWU Münster, Institute of Metal Research • 31 years engaged in Powder Metallurgy starting at the Krebsöge Group 1981 and from 1997 – 2012 at GKN Powder Metallurgy • Responsibilities: Technology-Management, R&D, Quality, Health and Safety, Innovation Management ...... • Topics / experiences: Materials research, full process chain of press / sinter / forge / MIM, spray compaction (Aluminum), gear rolling, metallic filters, integration of CAD systems, modeling, simulation and testing (parts and processes), furnace and press technologies (incl. tool production) • Materials: Steels, tool steels, super alloys, aluminum, MMC… Powder Metallurgy Powder (PM) for 2 Contents 1. Introduction: Why PM? 2. A quick History of PM Beginners 3. Key PM Processes and Applications 1. Powder Production 2. Sintering Process 3. Axial Compaction (Press and Sinter) 4. Hot Isostatic Pressing (HIP) 5. Metal Injection Molding (MIM) 6. Additive Manufacturing (AM, 3D Printing) 4. Conclusions and Outlook Powder Metallurgy Powder (PM) for Most videos, shown in this presentation, can be found on YouTube 3 Contents 1. Introduction: Why PM? 2. A quick History of PM Beginners 3. Key PM Processes and Applications 1. Powder Production 2. Sintering Process 3. Axial Compaction (Press and Sinter) 4. Hot Isostatic Pressing (HIP) 5. Metal Injection Molding (MIM) 6. Additive Manufacturing (AM, 3D Printing) 4. Conclusions and Outlook Powder Metallurgy Powder (PM) for 4 Methods for the Processing of Metal Powders to high / full Density Definition of Sintering (ISO): Sintering is the thermal treatment of a powder or Beginners compact, at a temperature below the melting point of the main constituent, for the Powder Forging purpose of increasing its (via Press and Sinter) strength by the metallurgical bonding of its particles. HIP Additive Press, MIM, 3D Print and Sinter Manufacturing Powder Metallurgy Powder (PM) for 5 ASM Handbook, Vol. 7, Powder Metallurgy, p. 13 Why using PM Technology? Properties: Geometry: The material – PM is – Beginners 1. cannot be manufactured by any 1. the alternative with the superior other method: economical advantages e.g. hard metals, magnets, compared to the conventional refractories, porous structures... production processes (machining, cold / hot forming, 2. achieves via the specific PM- casting…) by applying net shape processes, e.g. powder processing (e.g. MIM, net shape production (rapid solidification compaction (axial, CIP or HIP...)). or mechanical alloying), properties, which may be 2. Capable, as a net shape process, destroyed by applying to generate geometries, which conventional processes cannot be manufactured by other (temperatures, deformation, methods at all (This holds times). PM-processes are able to maintain a good portion of the especially for Additive special properties. Manufacturing / 3 D Printing). Powder Metallurgy Powder (PM) for 6 Why using PM Technology? Beginners Powder Metallurgy Powder (PM) for 7 ASM Handbook, Vol. 7, Powder Metallurgy, p. 9 Material and Energy Considerations Beginners The old fashioned way The better alternative Powder Metallurgy Powder (PM) for 8 Courtesy Kobe Steel Material and Energy Considerations Beginners Press and Sinter Powder Metallurgy Powder (PM) for 9 EPMA, Vision 2025, p. 7, www.epma.com Material and Energy Considerations Beginners The old fashioned way The better alternative Powder Metallurgy Powder (PM) for 10 Courtesy Kobe Steel Material and Energy Considerations mech.Machining Bearbeitung CastingGießen Beginners SchmiedenForging PulvermetallurgiePowder Press and Sinter Metallurgy 0 4 8 12 16 kWh/kg • These values include the energy consumption for the production of the raw materials (powder, steel, ingot) • The numbers are based on public domain data (e.g. industry reports) and individual studies in literature • A generally valid comparison is nearly impossible without focusing on specific components – the scatter between the processes and different operations is high Powder Metallurgy Powder (PM) for Vladislav Kruzhanov, Volker Arnhold, Energy Consumption in PM Manufacturing, 11 Powder Metallurgy, 2012 vol. 55, p. 14 Energy Consumption in different PM Operations (GKN Sinter Metals – 26 operations) Beginners Special processes / materials lead to the very high range: Powder Metallurgy Powder (PM) for MIM, Powder Forging, Filters, Aluminum, Bronze, Stainless Steels… 12 Vladislav Kruzhanov, Volker Arnhold, Energy Consumption in PM Manufacturing, Euro PM2011, Barcelona, October 10 Contents 1. Introduction: Why PM? 2. A quick History of PM Beginners 3. Key PM Processes and Applications 1. Powder Production 2. Sintering Process 3. Axial Compaction (Press and Sinter) 4. Hot Isostatic Pressing (HIP) 5. Metal Injection Molding (MIM) 6. Additive Manufacturing (AM, 3D Printing) 4. Conclusions and Outlook Powder Metallurgy Powder (PM) for 13 Key PM Developments Beginners ASM Handbook, Vol. 7, Powder Metallurgy, p. 3 Powder Metallurgy Powder (PM) for 14 Key PM Developments (1826-1865) Beginners Powder Metallurgy Powder (PM) for 15 Key PM Developments (1878-1900) Beginners Powder Metallurgy Powder (PM) for 16 Key PM Developments (1920ies ) Beginners Powder Metallurgy Powder (PM) for 17 Key PM Developments (1920ies ) Beginners Powder Metallurgy Powder (PM) for 18 Key PM Developments (1920ies ) Beginners Powder Metallurgy Powder (PM) for 19 Key PM Developments (1930ies ) Beginners via www.epma.com Powder Metallurgy Powder (PM) for 20 Key PM Developments (1930ies ) Beginners Powder Metallurgy Powder (PM) for 21 Key PM Developments (1950ies ) Beginners Powder Metallurgy Powder (PM) for 22 Key PM Developments (1950ies ) Beginners Powder Metallurgy Powder (PM) for 23 Powder Metallurgy (PM) for Beginners European PM today: Production kt Production in today: European PM 24 European PM today: Production in Billion € Beginners Powder Metallurgy Powder (PM) for 25 EU is the largest PM sector globally* (by value) Beginners * If we separate Asia Pacific and Japan Powder Metallurgy Powder (PM) for 26 The Powder Metallurgy Technology Portfolio Beginners Powder Metallurgy Powder (PM) for Courtesy GKN Sinter Metals 27 Powder Metallurgy (PM) for Beginners History of the ‘PM tree’ as covered covered by EPMA as tree’ ‘PM ofthe History 28 Contents 1. Introduction: Why PM? 2. A quick History of PM Beginners 3. Key PM Processes and Applications 1. Powder Production 2. Sintering Process 3. Axial Compaction (Press and Sinter) 4. Hot Isostatic Pressing (HIP) 5. Metal Injection Molding (MIM) 6. Additive Manufacturing (AM, 3D Printing) 4. Conclusions and Outlook Powder Metallurgy Powder (PM) for 29 Chemical Methods: Electrolysis Beginners • The raw material is dissolved at the anode and deposited at the cathode. • The external voltage drives the deposition process. • A warm bath using high viscosity electrolytes and minimal agitation ensures a loose cathode. • After deposition, the cathode deposit is washed, dried, ground, screened and annealed Powder Metallurgy Powder (PM) for to form a powder. 30 • The powders are irregular porous and show dendritic shape. Chemical Methods: Carbonyl Process Fe + 5 CO Fe (CO)5 Ni + 4 CO Ni (CO)4 Beginners Fe (CO)5 Fe + 5 CO Ni (CO)4 Ni + 4 CO • When iron or nickel ores (based on oxide) react under high pressure at elevated temperatures with carbon monoxide, iron pentacarbonyl or nickel tetracarbonyl are formed. • Both compounds are in the liquid state. Because of their low boiling temperatures (103°C (Fe- carbonyl) and 43°C (Ni-carbonyl)), they can be easily purified by distillation. Both decompose to metal powder and CO. • Carbonyl powders are usually high purity powders, spherical and very small (< few micrometers). • Because of the very small size, carbonyl powders show a low flowability and cannot be used for classical press and sintered parts. Except for Ni, which is a popular alloying additive. Powder Metallurgy Powder (PM) for • Carbonyl iron and nickel powders are widely used in the MIM manufacturing of low alloyed 31 steels. Chemical Methods: Sponge Iron Process Beginners Courtesy Höganäs AB Powder Metallurgy Powder (PM) for 32 Melt Atomization (Water): Irregular Powder • Water atomization is the most applied method for the production of iron and (low alloyed) steel powders Beginners for the press and sinter process. • The molten metal (starting from scrap) is disintegrated by multiple water jets streams. High pressure water jets are directed against the melt stream, forcing disintegration and rapid solidification. • The powders have an irregular shape and a rather wide size distribution (mostly between 50 and Powder Metallurgy Powder (PM) for 250 micrometer). 33 Powder Preparation • For the production of structural parts we need Fe-alloy powder mixes. Fully pre-alloyed steel powder is too hard to be compacted to high density.
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