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Axisymmetric closed die forging of aluminium powder components
Use of polycrystalline boron nitride and ceramic tools in machining hard die and tool steels was discussed. Data for tool life was presented for a range of materials in turning and end-milling operations. Temperatures up to 1550°C were estimated in the cutting zone when machining hardened E52100 steel with PCBN tools.
The need to correct deficiencies in PM parts, low mechanical properties caused by residual porosity and/or inappropriate
A study of processing Fe alloyed with Cu, Ni, MO and C was undertaken with the object of optimizing process conditions for
alloying, prior to expanding the market for PM parts, was discussed with emphasis on automotive power train components. By
enhanced properties at densities of about 7.1 gm.cm~“. The need for identification of key parameters was emphasized and a variable search method was used to this end. These parameters were closely controlled and tolerances in others were
INVESTIGATIONS
strategies, with cost advantages, Examples were given.
TREATMENT
OF HEAT
OF HARDMETALS
M. Szutkowska,
G. Tadeusz.
(Inst. of Metal
Cutting, Poland.) Invest,igations aimed at increasing strength and durability of hardmetals, by increasing the strength of the binder phase by heat treatment, were described. In the case of WC-Co physico-chemical modifications were found which increased the binder strength by dissolved C. Increased indentation fracture toughness and cutting performance were reported. Comparison was made with coated cutting tool inserts. MECHANICAL
AND CUTTING
PERFORMANCE
OF BINDER
RICH
CERMETS et al.
(University
of
Genoa,
Genoa, Italy.) It was reported that binder rich cermets, based on TiN, TIC, WC, Ni, Co and W had been made by PM methods. Structure, properties and cutting performance were investigated with regard to process variables and the use of PVD coatings. Continuous and interupted cutting tests were used. CONGRESS
METALLURGY:
were
follow
OF POW-
The abstracts
are of papers
presented
at
the
which
Congress,
which was held in Washington
DC,
USA, in June 1996.
is needed.
MAGTNETIC
Dynamic
HIGH TEMPERATURE
Research
magnetic
Inc., USA.)
compaction,
were
attained.
It
parts
and uniform
was
with
for
reported
aspect
that
ratios
2O:l
density had been made.
Structure/property relationships in PM materials
Ryan.
(Windfall
examination
OF FERROUS
Products
provided
Inc.,
by
of PM metals
St.
microscopic was
reviewed
with consideration of structure/property relationships, application to product, process and
design
uneven
materials grain
and quality control. distribution
detected.
incomplete
transformation Changes process
induced
alloying,
retained
products
in magnetic
are
to magnetic
sintering,
and
C
in
can be evaluated.
behaviour,
structural
related
changes,
to
were
discussed.
FATIGUE
OF HIGH DENSITY FERROUS
PM MATERIALS H.G. Rutz et al. (Hoeganaes
SINGLE DENSITY
COMPACTION
FOR HIGH
IN FERROUS MATERIALS
FOR AUTOMOTIVE
APPLICATIONS
H. Rutz et al. (Hoeganaes Corp, Riverton, USA.) The use of ANCORDENSE system powders to make parts with high density was discussed. Higher green strength and lower ejection loads were shown to be attained. Advantages were reviewed with respect to experience. Machining of green parts was shown to be possible.
ADVANCED
STRATEGIES
HIGH ENDURANCE
FOR PM
Carp, Riverton,
USA.) Investigations of microstructures, rotating bending fatigue and fatigue mechanisms of a range of high performance PM steels was described. The ANCORDENSE system was used to at,tain high green density and was followed by conventional and high temperature sintering. Relationships between structure and properties were described.
High performance PARAMETERS
materials
OF SINTERING FOR HIGH STRENGTH
LOW ALLOY STEELS
PARTS R.M. German P.K. Jones et al. (Stackpole
54
MPR May 1997
Ltd., USA.)
to
et
al.
(Pennsylvania
University, Pennsylvania,
Engineering
produce
from multi-component
were described. outlined.
materials
parts
85:X dense
conditions
were
College,
sound
sintered
Al alloy preforms
Process
Pressed
were
hot
and
extruded.
HOT FORMING OF SINTERED PREFORMS
OF ULTRA-HIGH
STRENGTH
STEELS
K.S. Pandey.
(Regional
ge, India.) Densification multicomponent investigated. protect was
of
USA.)
State
POWDER
Engineering
sintered
Colle-
85%
dense steel was
Ceramic
against less
and
4130 and 4140 upset at 115O”C, coating
were used to
oxidation.
rapid
Densification
than
Densification
in
was
pure
Fe.
described
mathematically. AXISYMMETRIC
CLOSED DIE
FORGING OF ALUMINIUM
POWDER
COMPONENTS (Indian
Inst.
of Technology, Kharagpur, India.) Forging of PM parts was discussed. paper reported an investigation
The of
technological sintered study
M.M.Gadkhindi.
aspects
of
Al preforms
concentrated
and geometry
cold
in closed on
density
in order to obtain
forging dies.
of The
variations defect free
parts. It was expected
that the study would
lead to improved deformation patterns
understanding in forging.
of
Metal injection POWDER-BINDER IN INJECTION
OPTIMIZATION DENSIFICATION
K.S. Pandey. (Regional India.) Experiments
G. Sutradhar,
EFFECTOFMICROSTRUCTUREON
Innovations in ferrous ciensifica tion process
POWDER PREFORMS
preforms,
Cracks
of porosity
In relation
growth,
OF
SINTERED
Properties were analysed. MoSz graphite were used as lubricants.
PM MATERIALS D.
ALUMINIUM
sintered
PROPERTIES
Mary’s, USA.) Information
EXTRUSION
MULTI-COMPONENT
attainment of high parts density, was outlined. Densities of 7.5 to 7.6 gm.cm~” cylindrical
in order to reduce costs without
Hot forming
COMPACTION
FORCES
J. Barber et al. (IW
broadened
loss in final properties.
TO HIGH DENSITY USING PULSED
readily
1996 WORLD which
DYNAMIC MAGNETIC
MAGNETIC
M. Capurro
DER
reference to a range of parts it was shown that no one densification process meets the requirements of every part and a range of
J.
Kihara
et
FLOW SIMULATION
MOULDING al.
(University
of
Tokyo,
Tokyo, Japan.) It was reported that finite element methods had been used to simulate flow and heat transfer in injection moulding. That model was limited to thin sections. A more
general
simulation
model,
for thick
The need to correct deficiencies in PM parts, low mechanical properties caused by residual porosity and/or inappropriate
A study of processing Fe alloyed with Cu, Ni, MO and C was undertaken with the object of optimizing process conditions for
alloying, prior to expanding the market for PM parts, was discussed with emphasis on automotive power train components. By
enhanced properties at densities of about 7.1 gm.cm~“. The need for identification of key parameters was emphasized and a variable search method was used to this end. These parameters were closely controlled and tolerances in others were
INVESTIGATIONS
strategies, with cost advantages, Examples were given.
TREATMENT
OF HEAT
OF HARDMETALS
M. Szutkowska,
G. Tadeusz.
(Inst. of Metal
Cutting, Poland.) Invest,igations aimed at increasing strength and durability of hardmetals, by increasing the strength of the binder phase by heat treatment, were described. In the case of WC-Co physico-chemical modifications were found which increased the binder strength by dissolved C. Increased indentation fracture toughness and cutting performance were reported. Comparison was made with coated cutting tool inserts. MECHANICAL
AND CUTTING
PERFORMANCE
OF BINDER
RICH
CERMETS et al.
(University
of
Genoa,
Genoa, Italy.) It was reported that binder rich cermets, based on TiN, TIC, WC, Ni, Co and W had been made by PM methods. Structure, properties and cutting performance were investigated with regard to process variables and the use of PVD coatings. Continuous and interupted cutting tests were used. CONGRESS
METALLURGY:
were
follow
OF POW-
The abstracts
are of papers
presented
at
the
which
Congress,
which was held in Washington
DC,
USA, in June 1996.
is needed.
MAGTNETIC
Dynamic
HIGH TEMPERATURE
Research
magnetic
Inc., USA.)
compaction,
were
attained.
It
parts
and uniform
was
with
for
reported
aspect
that
ratios
2O:l
density had been made.
Structure/property relationships in PM materials
Ryan.
(Windfall
examination
OF FERROUS
Products
provided
Inc.,
by
of PM metals
St.
microscopic was
reviewed
with consideration of structure/property relationships, application to product, process and
design
uneven
materials grain
and quality control. distribution
detected.
incomplete
transformation Changes process
induced
alloying,
retained
products
in magnetic
are
to magnetic
sintering,
and
C
in
can be evaluated.
behaviour,
structural
related
changes,
to
were
discussed.
FATIGUE
OF HIGH DENSITY FERROUS
PM MATERIALS H.G. Rutz et al. (Hoeganaes
SINGLE DENSITY
COMPACTION
FOR HIGH
IN FERROUS MATERIALS
FOR AUTOMOTIVE
APPLICATIONS
H. Rutz et al. (Hoeganaes Corp, Riverton, USA.) The use of ANCORDENSE system powders to make parts with high density was discussed. Higher green strength and lower ejection loads were shown to be attained. Advantages were reviewed with respect to experience. Machining of green parts was shown to be possible.
ADVANCED
STRATEGIES
HIGH ENDURANCE
FOR PM
Carp, Riverton,
USA.) Investigations of microstructures, rotating bending fatigue and fatigue mechanisms of a range of high performance PM steels was described. The ANCORDENSE system was used to at,tain high green density and was followed by conventional and high temperature sintering. Relationships between structure and properties were described.
High performance PARAMETERS
materials
OF SINTERING FOR HIGH STRENGTH
LOW ALLOY STEELS
PARTS R.M. German P.K. Jones et al. (Stackpole
54
MPR May 1997
Ltd., USA.)
to
et
al.
(Pennsylvania
University, Pennsylvania,
Engineering
produce
from multi-component
were described. outlined.
materials
parts
85:X dense
conditions
were
College,
sound
sintered
Al alloy preforms
Process
Pressed
were
hot
and
extruded.
HOT FORMING OF SINTERED PREFORMS
OF ULTRA-HIGH
STRENGTH
STEELS
K.S. Pandey.
(Regional
ge, India.) Densification multicomponent investigated. protect was
of
USA.)
State
POWDER
Engineering
sintered
Colle-
85%
dense steel was
Ceramic
against less
and
4130 and 4140 upset at 115O”C, coating
were used to
oxidation.
rapid
Densification
than
Densification
in
was
pure
Fe.
described
mathematically. AXISYMMETRIC
CLOSED DIE
FORGING OF ALUMINIUM
POWDER
COMPONENTS (Indian
Inst.
of Technology, Kharagpur, India.) Forging of PM parts was discussed. paper reported an investigation
The of
technological sintered study
M.M.Gadkhindi.
aspects
of
Al preforms
concentrated
and geometry
cold
in closed on
density
in order to obtain
forging dies.
of The
variations defect free
parts. It was expected
that the study would
lead to improved deformation patterns
understanding in forging.
of
Metal injection POWDER-BINDER IN INJECTION
OPTIMIZATION DENSIFICATION
K.S. Pandey. (Regional India.) Experiments
G. Sutradhar,
EFFECTOFMICROSTRUCTUREON
Innovations in ferrous ciensifica tion process
POWDER PREFORMS
preforms,
Cracks
of porosity
In relation
growth,
OF
SINTERED
Properties were analysed. MoSz graphite were used as lubricants.
PM MATERIALS D.
ALUMINIUM
sintered
PROPERTIES
Mary’s, USA.) Information
EXTRUSION
MULTI-COMPONENT
attainment of high parts density, was outlined. Densities of 7.5 to 7.6 gm.cm~” cylindrical
in order to reduce costs without
Hot forming
COMPACTION
FORCES
J. Barber et al. (IW
broadened
loss in final properties.
TO HIGH DENSITY USING PULSED
readily
1996 WORLD which
DYNAMIC MAGNETIC
MAGNETIC
M. Capurro
DER
reference to a range of parts it was shown that no one densification process meets the requirements of every part and a range of
J.
Kihara
et
FLOW SIMULATION
MOULDING al.
(University
of
Tokyo,
Tokyo, Japan.) It was reported that finite element methods had been used to simulate flow and heat transfer in injection moulding. That model was limited to thin sections. A more
general
simulation
model,
for thick