manganese as a primary alloying element dennis hammond –apex advanced technologies richard r....
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Manganese as Manganese as a primary a primary alloying alloying element element Dennis Hammond –Apex Dennis Hammond –Apex Advanced TechnologiesAdvanced Technologies
Richard R. Phillips – Engineered Richard R. Phillips – Engineered Pressed MaterialsPressed Materials
Manganese BackgroundManganese Background Manganese metal admixed subject to Manganese metal admixed subject to
HydrolysisHydrolysis , oxidation in P/M application, oxidation in P/M application Manganese as a pre-alloy, hard to Manganese as a pre-alloy, hard to
compress, limited use levelscompress, limited use levels Ferro Manganese abrasive, patentsFerro Manganese abrasive, patents Highest performance alloying element- Highest performance alloying element-
strength, hardenabilitystrength, hardenability Previous work demonstrated feasibility of Previous work demonstrated feasibility of
using Manganese metal admixed both as a using Manganese metal admixed both as a sinter hardened and case hardened lean sinter hardened and case hardened lean formulationsformulations
Manganese Background Manganese Background Cont.Cont.
Manganese as an admix demonstrated Manganese as an admix demonstrated feasibility in multiple production furnaces in feasibility in multiple production furnaces in previous workprevious work
Manganese coated for protection from Manganese coated for protection from hydrolysis and oxidation during blending, hydrolysis and oxidation during blending, storage and handling, supplied as master storage and handling, supplied as master batch batch
Press conditions developed for maximizing Press conditions developed for maximizing protection during de-lubing and sinteringprotection during de-lubing and sintering
Key FeaturesKey FeaturesAdditive/Lubricant Master BatchAdditive/Lubricant Master Batch
Calculations for feasibility of density, Calculations for feasibility of density, desired lubrication, and needed additivesdesired lubrication, and needed additives
Target volume 98.5-99.5% of theoretical at Target volume 98.5-99.5% of theoretical at target green densitytarget green density
Need for a green compact free of density Need for a green compact free of density gradients, semi-hydrostatic gradients, semi-hydrostatic
Need for excellent lubrication, Apex Need for excellent lubrication, Apex SuperlubeSuperlube®®
Need for mobile lubricant to achieve best fit Need for mobile lubricant to achieve best fit of metal particles during compaction and of metal particles during compaction and spread of additivesspread of additives
Key FeaturesKey FeaturesAdditive/Lubricant Master BatchAdditive/Lubricant Master Batch
Need for excellent distribution and Need for excellent distribution and dispersion of additives in a segregation dispersion of additives in a segregation free powder mix and compactfree powder mix and compact
Protection of reactive additives by coating Protection of reactive additives by coating particlesparticles
Master batch includes all additives Master batch includes all additives including proprietary additives, pre-mixed including proprietary additives, pre-mixed and screened, ready to mix with iron and screened, ready to mix with iron powder for easy mixingpowder for easy mixing
Test Matrix for Test Matrix for evaluationevaluation Fixed Density -7.25g/cc greenFixed Density -7.25g/cc green
Fixed Carbon- 0.3%Fixed Carbon- 0.3% Compressible iron- AT1001HPCompressible iron- AT1001HP Mn content- 0%, 0.5%, 0.75%, 1%,1.5%, Mn content- 0%, 0.5%, 0.75%, 1%,1.5%,
2%2% Sintering- in various production Sintering- in various production
furnaces, conventional gas 2050furnaces, conventional gas 2050F, rapid F, rapid cool 2050cool 2050F and 2265F and 2265F, rapid cool F, rapid cool vacuum 2265vacuum 2265F and 2350F and 2350FF
Test Matrix for Test Matrix for evaluationevaluation
Heat treatment- .6%carbon potential, Heat treatment- .6%carbon potential, temper at 350Ftemper at 350F
Test- carbon content, size change, Test- carbon content, size change, sintered density, TRS strength, sintered density, TRS strength, hardness, and Impact hardness, and Impact
Carbon content after Carbon content after Sintering 2050 F slow Sintering 2050 F slow
coolcool% Mn % C before sinter % C after Sinter
0 0.3% 0.26%
0.5% 0.3% 0.29%
0.75% 0.3% 0.29%
1% 0.3% 0.29%
1.5% 0.3% 0.29%
2% 0.3% 0.30%
Conclusions- Carbon lossConclusions- Carbon loss
Less losses of Graphite with Manganese Less losses of Graphite with Manganese than with plain ironthan with plain iron
Manganese well protected using this Manganese well protected using this coating technologycoating technology
6.95
7
7.05
7.1
7.15
7.2
7.25
7.3
De
ns
ity
(g
/cm
3)
0% Mn 0.5% Mn 0.75%Mn
1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn Steel Density vs Mn Content
for Various Sintering Processes in the as Sintered Condition
2050F 1121C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum
7
7.05
7.1
7.15
7.2
7.25
7.3
Den
sity
(g
/cm
3 )
0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn Steel Density vs. Mn Content
for Various Sintering Processes with Heat Treating and Temper at 350F
2050F 1121C slow cool gas HT 2265F 1240C fast cool vacuum HT2265F 1240C fast cool gas HT 2350F 1288C fast cool vacuum HT
-0.40%
-0.30%
-0.20%
-0.10%
0.00%
0.10%
0.20%
0.30%
0.40%
0.50%
0.60%
0.70%
0.80%
% S
ize c
ha
ng
e
0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn Steel Size Change from Die Size vs Mn Content
of Various Sintering Processes in the as Sintered Condition
as molded 2050F 1121C slow cool gas2265F 1240C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum
-0.40%
-0.30%
-0.20%
-0.10%
0.00%
0.10%
0.20%
0.30%
0.40%
0.50%
0.60%
0.70%
0.80%
Siz
e C
han
ge
0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn SteelSize Change from Die Size vs. Mn Content
of Various Sintering Processes with Heat Treating and Temper at 350F
As molded 2050F 1121C slow cooled gas HT
2050F 1121C fast cooled gas HT 2265F 1240C fast cooled gas HT
2265F 1240C fast cooled vacuum HT 2350F 1288C fast cooled vacuum HT
Conclusions- density and Conclusions- density and sizesize
Higher sintering temperature results in Higher sintering temperature results in higher sintered densityhigher sintered density
Increased Mn leads to increased growth Increased Mn leads to increased growth Sintering1% Mn at 2265F/1240C appears Sintering1% Mn at 2265F/1240C appears
optimum for densityoptimum for density 0.75 to1% Mn gives near neutral growth 0.75 to1% Mn gives near neutral growth
<0.1% change considered to be ideal <0.1% change considered to be ideal
0
20
40
60
80
100
120
140
160
180
TRS
Str
engt
h
0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn Steel TRS Strength vs. Mn Content
for Various Sintereing Processes as Sintered Condition
2050F 1121C fast cooled gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum
0
20
40
60
80
100
120
140
160
180
TR
S S
tren
gth
0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn SteelTRS Strength vs. Mn Content
for Various Sintereing Process in the Heat Treating and Temper at 350F
2050F 1121C slow cool gas 2265F 1240C fast cool vacuum2265F 1240C fast cool gas 2350F 1288C fast cool vacuum
Conclusions –TRS Conclusions –TRS StrengthStrength
0.75% Mn appears to be optimum for 0.75% Mn appears to be optimum for TRSTRS
Near 100% improvement in strength at Near 100% improvement in strength at higher temperatures over 2050F/1121Chigher temperatures over 2050F/1121C
Heat treated 0.5% Mn gives optimum Heat treated 0.5% Mn gives optimum results results
30
40
50
60
70
80
90
Har
dn
ess
HR
B
0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn SteelHardness vs. Mn Content
for Various Sintering Processes as Sintered Condition
2050F 1121C slow cool gas 2050F 1121C fast cool gas2265F 1240C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum
30
32
34
36
38
40
42
44
46
48
50
Ha
rdn
es
s H
RC
0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn SteelHardness vs. Mn Content
of Various Sintering Processes with Heat Treating and 350F Temper
2050F 1121C slow cool gas HT 2265F 1240C fast cool gas HT2265F 1240C fast cool vacuum HT 2350F 1288C fast cool vacuum HT
Conclusions- hardnessConclusions- hardness
As sintered general improvement in As sintered general improvement in hardness with increased Mn contenthardness with increased Mn content
Hardness after heat treatment no Hardness after heat treatment no significant improvement after 0.75% Mnsignificant improvement after 0.75% Mn
Hardness after heat treatment with Hardness after heat treatment with 0.75% Mn all 44 HRC and above 0.75% Mn all 44 HRC and above
0
5
10
15
20
25
30
35
40
45
Imp
act
ft-l
bs.
0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn SteelImpact vs. Mn content
of Various Sintering Processes as Sintered Condition
2050F 1121C slow cool gas 2050F 1121C fast cool gas2265F 1240C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum
0
2
4
6
8
10
Imp
act
ft-l
bs.
0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn
MPIF 2011 Mn SteelImpact vs. Mn Content
of Various Sintering Processes with Heat Treating and a Temper of 350T
2050F 1121C slow cool gas HT 2050F 1121C fast cool gas HT2265F 1240C fast cool gas HT 2265F 1240C fast cool vacuum HT2350F 1288C fast cool Vacuum HT
Conclusions -ImpactConclusions -Impact
0.5% -0.75% Mn optimum for impact0.5% -0.75% Mn optimum for impact Fast cooling gas furnace gave the best Fast cooling gas furnace gave the best
impact impact Mn coupled with higher temperature Mn coupled with higher temperature
sintering can give dramatic sintering can give dramatic improvements of impact strength improvements of impact strength
Over all conclusionsOver all conclusions Elemental Mn can be protected and Elemental Mn can be protected and
effectively used in powdered metaleffectively used in powdered metal No significant carbon lossNo significant carbon loss No compromise of compressibilityNo compromise of compressibility Properties can generally be improved Properties can generally be improved
with Mn levels of 0.5 to 1%with Mn levels of 0.5 to 1% Increased sintering temperature gives Increased sintering temperature gives
improved properties with Mn containing improved properties with Mn containing formulasformulas
Over all conclusions, Over all conclusions, Cont.Cont.
Mn can be a cost effective alloying Mn can be a cost effective alloying element element
Mn can be used in powdered metal on Mn can be used in powdered metal on convention sintering furnacesconvention sintering furnaces
Mn can be substituted for other more Mn can be substituted for other more costly alloying elements costly alloying elements