Cost effective, high density P/M parts with existing equipment
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Transcript of Cost effective, high density P/M parts with existing equipment
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Cost effective, high density P/M parts with existing equipment
By Dennis Hammond
Apex Advanced Technologies, LLC
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Requirements to obtain high density
The level of lubricant used must be reduced, while not negatively impacting the part or processThe lubricant must be mobile, so that it migrates during pressingThe lubricant must be more effectiveThe lubricant must be effectively removed during the sintering process
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Effect of lubricant on density FN 0205
Lube Wt. %
1.00% .75% .50% .35% .30%
Lube vol. %
6.99% 5.33% 3.63% 2.56% 2.20%
Pore Free Den.
7.21 7.33 7.46 7.55 7.58
98% pore Free Den.
7.07 7.18 7.31 7.40 7.43
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• Solids as a general rule increase their melting point with increased pressure
• There are exceptions to the rule e.g. ice
• Clapeyron - Clausius formula predicts that when the density of a substance in its solid state is less than the density of the substance in its liquid state, then the melting point of that substance will decrease when pressure is increased
Physical State
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• Rheology - Study of the deformation and flow of matter in terms of stress, strain and time
• Useful in modeling behavior of a substance in a process and process control
• Example - processing polymers, paints, coatings and adhesives
Rheology
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• There are different types of rheometers for different applications
• We are using data from a capillary rheometer to model behavior from our lubricant
Rheology - cont.
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Heaters
Capillary Rheometer
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10
100
1000
10000
100000
10 100 1000 10000
Shear Rate (1/s)
Vis
cosi
ty (
Pa∙
s)
Dilatant
Newtonian
Pseudoplastic
Most polymeric materials are pseudoplastic (shear thinning)
Basic Curve Shapes
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Rheology - cont.Shear
Rate
1/s
30C
86F
PSI
30C
86F
Pa S
38C
100F
PSI
38C
100F
Pa S
60C
140F
PSI
60C
140F
Pa S
1000 8531 726 3851 328 1170 100
2000 8364 355 3998 170 1338 57
5000 7732 132 4043 69 1602 27
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Rheology - cont.Conclusion - hard solid with crystallinity that flowed from a solid to a liquid under pressureHigher temperature with pressure and shear reduced the viscosityP/M press has speed/shear, temperature due to particle to particle friction and compaction pressurePressures needed are at the low end of pressure used in a press, allowing for easy rearrangementModeling the lubricant in a rheometer could be expected to provide predictable results in a P/M press
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Ejection Forces
Do we have a better lubricant for P/M ?
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Breakaway Force FC0208 MP32 Base
1700
1900
2100
2300
2500
TSI
Lbs.
.75 Zinc Sterate 1953 2143 2320
.75 Acrawax 1977 2300 2486
.75 PS-1000b 1769 1793 1942
40 50 60
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Strip Force FC0208 MP32 Base
1200
1400
1600
1800
2000
TSI
Lb
s.
.75 Zinc Sterate 1575 1797 1941
.75 Acrawax 1450 1558 1633
.75 PS-1000b 1208 1358 1483
40 50 60
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Density FC0208 MP32 Base
6.75
6.80
6.85
6.90
6.95
7.00
TSI
Dens
ity G
/CC
.75 Zinc Sterate 6.77 6.89 6.98
.75 Acrawax 6.76 6.89 6.97
.75 PS-1000b 6.79 6.93 7.00
40 50 60
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Hoeganaes A737SH Cu Graphite
Comparative Green Densities
6.60
6.70
6.80
6.90
7.00
7.10
7.20
7.30
30 40 50 60
TSI
De
ns
itie
s
0.30%APEX PS 1000b.75%Acrawax
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Hoeganaes 85 HP Cu GraphiteComparative Green Densities
6.80
6.90
7.00
7.10
7.20
7.30
7.40
40 50 60
TSI
Den
siti
es
0.30%APEX PS 1000b.75%Acraw ax
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Hoeganaes 85 HP Ni, GraphiteComparative Green Densities
7.00
7.05
7.10
7.15
7.20
7.25
7.30
7.35
7.40
40 50 60
TSI
Den
siti
es 0.25% APEXPS 1000 b
.75%Acraw ax
0.30% APEXPS 1000b
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Hoeganaes Distalloy 4800A GraphiteComparative Green Densities
7.00
7.05
7.10
7.15
7.20
7.25
7.30
7.35
7.40
40 50 60
TSI
Den
siti
es
0.25% APEX PS 1000 b
.75%Acraw ax
0.30% APEX PS 1000b
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Hoeganaes A1000C Ni GraphiteComparative Green Densities
7.10
7.15
7.20
7.25
7.30
7.35
7.40
40 50 60
TSI
Den
siti
es .75%Acraw ax
0.30% APEX PS 1000b
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Domfer MP32 Cu GraphiteComparative Green Densities
6.406.506.606.706.806.907.007.107.20
30 40 50 60
TSI
Dens
ities
0.25% APEXPS 1000 b
0.30% APEXPS 1000b
0.4% APEXPS 1000 b
2NSt .75%
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Domfer MP35 Cu GraphiteComparative Green Densities
6.70
6.80
6.90
7.00
7.10
7.20
7.30
30 40 50 60
TSI
Den
sitie
s
0.25% APEX PS 1000 b
0.30% APEX PS 1000b
0.4% APEXPS 1000 b
2NSt .75%
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NAH ASC 100.29 GraphiteComparative Green Densities
7.00
7.05
7.10
7.15
7.20
7.25
7.30
7.35
40 50 60
TSI
De
ns
itie
s
0.30%APEX PS 1000b
.75%Acrawax
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Kobelco 300 MC Ni GraphiteComparative Green Densities
7.00
7.05
7.10
7.15
7.20
7.25
7.30
7.35
40 50 60
TSI
De
ns
itie
s
0.25% APEX PS 1000 b
.75%Acrawax
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Kobelco 300 ME Graphite MNSComparative Green Densities
7.00
7.05
7.10
7.15
7.20
7.25
7.30
7.35
40 50 60
TSI
De
ns
itie
s
0.25%APEX PS 1000 b.66%Acrawax
0.30%APEX PS 1000b
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QMP 1001 Cu Graphite Comparative Green Densities
7.00
7.05
7.10
7.15
7.20
7.25
7.30
7.35
40 50 60
TSI
De
ns
itie
s
0.30%APEX PS 1000b
.75%Acrawax
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Green density g/cc compared to conventional
lubricantsTonnage
Tsi
.25%
PS-1000b
.3%
PS-1000b
.4% PS-1000b
30 Up to .08 Up to .07 Up to .07
40 Up to .08 Up to .08 Up to .06
50 Up to .12 Up to .10 Up to .10
60 Up to .16 Up to .14 Up to .13
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Green Density ConclusionsNice green density pick up is possible with a conventional pressNo delamination or micro-cracking observed up to 65 tsi with uniform hardness and porosity of part after sinteringSlope of compressibility curve has been shifted upwardProduction data is better than lab data, at low tonnage, due to friction (temperature) and speed (shear)We get green density improvements from both effective rearrangement and from lower use levels
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Burn Out
The ideal lubricant burns out cleanly from the furnace and in the parts, all blisters and cracks would be eliminated
Quantity and rate of emission reduced
More parts through the furnace with less problems in less time
Minimize EPA concerns
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Percent burned in disassociated ammonia
-
20.0
40.0
60.0
80.0
100.0
120.0
400 500 600 700 800 900 1000
Temperature in degrees F
Perc
ent b
urne
d
Lithium Stearate Zinc Stearate Acrawax C PS-1000b
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200lbs. Metal, Gas evolution, Weight of Lube
0
0.2
0.4
0.6
0.8
1
1.2
1.4
400 F 500 F 600 F 700 F 800 F 900 F 1000 FTemperature in Degrees F
Lube
wei
ght
Lithium Sterate .75% Zinc Sterate .75% Acrawax .75% PS-1000b .3%
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Weight of parts for equal gas evolution
0
200
400
600
800
1000
Weight of parts in Lbs.Lithium Sterate .75% PS-1000b .3% Zinc Sterate .75%
PS-1000b .3% Acrawax .75% PS-1000b .3%
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Sintered Properties
General Improvements as green density improves
Sintered properties are enhanced with an effective lubricant
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Hoeganaes A737 Cu GraphiteComparative Sintered Densities
6.50
6.60
6.70
6.80
6.90
7.00
7.10
7.20
30 40 50 60
TSI
Den
sitie
s
0.30% APEXPS 1000 b -SinteredDensity
0.75 %Acrawax -SinteredDensity
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Hoeganaes A737 Cu GraphiteComparative Sintered Tensile Strength
110
120
130
140
150
160
170
180
190
30 40 50 60
TSI
KS
I
0.30%APEX Lube-SinteredTRS0.75 %Acrawax -SinteredTRS
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Comparison of TRS/Sintered Density Ratio of FC0208 A737 base metal
14
16
18
20
22
24
26
30 40 50 60
TSI
Rat
io T
RS
/Sin
tere
d D
ensi
ty .30% ApexPS 1000bRatioTRS/Sintered Density
.75%ACRAWAX C RatioTRS/Sintered Density
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Hoeganaes A737 Cu GraphiteComparative Sintered Hardness
32
34
36
38
40
42
44
46
48
30 40 50 60
TSI
HR
C
0.30%APEX Lube-SinteredHRC0.75 %Acraw ax -SinteredHRC
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Comparison of Hardness/Sintered Density Ratio of FC0208A737 base metal
4
4.5
5
5.5
6
6.5
7
30 40 50 60
TSI
Har
dn
ess/
Sin
tere
d D
ensi
ty
Rat
io
.30% ApexPS 1000bRatioHardness/SinteredDensity
.75%ACRAWAX C RatioHardness/SinteredDensity
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QMP A-1001 Cu GraphiteComparative Sintered Densities
6.65
6.75
6.85
6.95
7.05
7.15
7.25
7.35
30 45 60
TSI
Den
siti
es
0.30% APEXPS 1000 b
0.75 %Acraw ax
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QMP A-1001 Cu GraphiteComparative Sintered Tensile Strength
120
130140
150160
170180
190200
210
30 45 60
TSI
KS
I
0.30% APEXPS 1000 b
0.75 %Acraw ax
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Comparison of TRS/Sintered Density ratio of FC0208of QMP A1001
17
19
21
23
25
27
30 45 60
TSI
Rat
io o
f T
RS
/Sin
tere
d D
ensi
ty
.30%ApexPS1000bRatioTRS/SinteredDensity
.75%ACRAWAX CRatioTRS/SinteredDensity
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QMPA-1001 Cu GraphiteComparative Sintered Hardness
70
75
80
85
90
95
30 45 60
TSI
HR
C 0.30% APEXPS 1000 b
0.75 %Acraw ax
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Comparison of TRS/Sintered Density ratio- FC208
0
5
10
15
20
25
30
30 45 60
TSI
Ratio
of T
RS/S
inte
red
Dens
ity
.30% ApexPS 1000bRatioTRS/SinteredDensity
.75%ACRAWAXC RatioTRS/SinteredDensity
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Kobelco MC300 base metal FN-0208 lube comparison
6.7
6.8
6.9
7
7.1
7.2
7.3
30 40 50 60
TSI
Sin
tere
d D
en
sit
y, g
/cc
Apex .3%SinteredDensity
Acrawax.75%SinteredDensity
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Kobelco MC300 base metal FN-0208 Lube comparison
90
95
100
105
110
115
120
125
130
135
30 40 50 60
TSI
Sin
tere
d T
RS
, KS
I
Apex .3%SinteredTRS
Acrawax.75%SinteredTRS
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Kobelco MC300 base metal FN-0208 lube comparison
13.5
14
14.5
15
15.5
16
16.5
17
17.5
18
18.5
30 40 50 60
TSI
TR
S/S
inte
red
de
ns
ity
ra
tio
Apex .3%TRS/SinteredDensity Ratio
Acrawax .75%TRS/SinteredDensity Ratio
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Kobelco MC300 base metal FN-0208 lube comparison
68
70
72
74
76
78
80
82
84
30 40 50 60
TSI
Sin
tere
d H
ard
ne
ss
, HR
B Apex .3%SinteredApparentHardness
Acrawax.75%SinteredApparentHardness
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Kobelco MC300 base metal FN-0208 lube comparison
10.1
10.3
10.5
10.7
10.9
11.1
11.3
11.5
30 40 50 60
TSI
HR
B/S
inte
red
De
ns
ity
Apex .3%HRB/SinteredDensity Ratio
Acrawax.75%HRB/SinteredDensity Ratio
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Current Applications
To obtain green density comparable to die wall, hot compaction or double press without micro cracking or delaminationTo replace internal lubrication in conventional die wall lubrication applicationsTo modify a compressibility curve to fit a press
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Current Applications Cont.
To debottleneck a furnace operationTo run high nickel formulas without blistering or cracksTo facilitate one step copper infiltration/sinteringTo obtain improved physical properties including TRS, hardness, and dimensional stability
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Current Applications Cont.
Improve die wear
Improve surface appearance from furnace condensation
Reduction of scrap rate
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Use Recommendations
.25%-.27% Apex PS-1000b for parts up to 3/8 inch
.3% Apex PS-1000b for parts 3/8 to 1 inch with moderate complexity
.35% Apex PS-1000b for parts with higher complexity or high surface area
.4% Apex PS-1000b for taller parts
Add .05% for non graphite containing mixes
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Products Available
Apex PS-1000b
Apex PS-1000b mixed with customers choice of graphite (66.6%/33.3%)
Apex PS-1000b mixed with graphite plus other additives desired to be distributed (e.g. Cab-O-Sil, Flowguard, MnS, etc.)
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Applications Not Recommended
FeSi and FeP formulas
6.8 to 7.0 green density applications
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Using a Lubricant to Minimize Segregation and
DustingLubricant’s viscosity is a function of shear and temperatureLubricant is attracted to graphite, copper, nickel and iron powderWe can achieve excellent adhesion between fines and the base iron powder, if we get the viscosity low enough to spread uniformly We can lower the viscosity using heat and shear using a medium intensity mixer
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Using a Lubricant to Minimize Segregation and
Dusting Cont.Lodige/ Littleford mixer
1) Preheat iron powder plus additives to
110C
2) Add .3% to .4% Apex PS-1000b, mix
for 4 minutes, screen
Dust resistance compared to untreated, excellent
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Using a Lubricant to Minimize Segregation and
Dusting Cont.1% graphite mix - 58% loss without treatment, 8% loss with treatment
Results similar to binder treated mixes
Lubricant and binder are one and the same
A low level of PS-1000b gives all of the benefits of non-dusting plus benefits of high density, properties, etc.