Apex Advanced Technologies, Inc.

Presented by: Dennis HammondContributor Richard Phillips

Using a highly effective lubricant in combination with a polymeric additive to minimize

cracking and address other process related problems

Presentation Outline• Overview of Superlube™, key

characteristics

• Overview of Enhancer and use

• Cracks/improved compactabilty

• Other processing problems

• Conclusions

Superlube™ Characteristics• Lubricant enters with the powdered metal as a

solid. Then transforms from a solid to a viscous liquid with shear, temperature, and pressure in the press

• Lubricant shear thins directly with shear stress• Direct results from solid to liquid transformation

– High density achievable - 7.2 to 7.4 g/cc– Low use levels required - typical 0.4% or less– Excellent lubricity - film of viscous liquid

versus slide on a solid particle

Direct results

• Up to 50% reduction in ejection force

• Tool wear decreased due to better lubrication and/or lowering of tonnage

• Surface finish improved

• Improved physical properties of final part by 15 - 20%

Direct Results Cont.

• Powder movement to equalize green density, near hydrostatic conditions in compaction (98-99.5vol. %)

• Minimization of density gradients in the part

• Elimination of micro-cracking• Reduces the risk of molding cracks• Staggered decomposition in burn off• Excellent dimensional stability of sintered

parts

Enhancer Characteristics

• Clean burning, no ash• Primary function is to occupy space,

secondary is lubrication• Needs to deform with no interference to

metal compressibility up to 100% vol.• Helps to improve green strength up to

100%- improved crack resistance• Compatible with mixing, compaction and

processing• Favorable cost / specific gravity ratio

Methods Used

• Predictable method based on calculation to optimize lubrication using lubricant and enhancer, target 98-99.5 Vol. %, near hydrostatic conditions

• Lubricant functions as die wall and internal lubricant simultaneously

• Enhancer used to occupy space, deform under load to enhance green strength

Cracks

• A crack can be defined as a break in interparticle bond between powder particles

• The bond may have been broken during processing or may have never been formed

• A major issue in P/M processing

• Once formed cannot be fixed

Cracks Root Causes

• Improper material composition

• Interparticle side shifting action

• Improper elastic strain release

• High tensile/shear stress

The Common Cracks in Green P/M Compacts

• 59 case studies of parts• When cracks were formed - In 19 cases during compaction - In 43 cases during ejection• Materials solutions - 18 cases increased green strength - 11 cases better lubrication - 4 cases improved powder compressibility - 2 cases better uniformity in compact - 2 cases improved handling

Crack Causes, Material Controlled

• High ejection load – better lubrication

• Low green strength - increase up to 100%

• Density gradients - near hydrostatic, limited lateral movement, 99% vol.

• Non-uniform porosity - small uniform pores

• Over compaction - movement in transition areas

Volume % vs. slideon Formulation FLN2-4405 at 7.0 g/cc G.D.

1175

1275

1375

1475

1575

1675

1775

1875

1975

Slid

e (L

bF

)

Slide 1875 2025 1992 1550 1400 1400 1325 1175

91.98% 96.93% 98.44% 98.94% 100.60%101.64%

0.75% Keno lube

0.75% Acra wax

- 0.35% -

0.35% 0.15%

0.35% 0.35%

0.35% 0.50%

0.35% 0.65%

0.35% 0.80%

Lube:

Enhancer:

Volume %:

Enhancer Effect on Ejection, Slide, and G.D. on A1000C at 60TSI

1400

1600

1800

2000

2200

2400

2600

Pea

k/S

lide

(TS

I)

7.23

7.26

7.29

7.32

7.35

7.38

7.41

7.44

slide 2583 1850 1625 1683 1458

G.D 7.37 7.42 7.41 7.38 7.30

97.34% 98.56% 100.00% 100.53% 101.29%Volume%

Green Strength

• Green strength increase directly with increased G.D.

• The more lubricant, the worse the green strength

• Green strength dependent on particle shape, irregularity and hardness

• Green strength dependent on type and amount of solids in the P/M mix

Green Strength

• Superlube™ is squeezed from between the particle surfaces

• Enhancer is deformed for best fit• The combination gives a unique mix that

allows for high green strength as well as excellent lubrication

• Combination used to achieve 99-99.5 vol. % at target density, the higher the density or the more volume occupied the less Enhancer is used

Acrawax Volume %: GS, TSIBase Iron ABC 100.30 at 7.0 g/cc

35

40

45

50

55

TS

I

1000

1500

2000

2500

3000

3500

4000

Green

Stren

gth

TSI 36.8 36 36.8 50

G. S. 3962 1785 1430 1336

Volume 89.29%

Volume 94.74%

Volume 97.41%

Volume 99.56%

0.35% Superlube + Enhancer Vol%: GS, TSI Base Iron ABC 100.30 at 7.0 g/cc

25

27

29

31

33

35

37

39

TS

I

2,000

2,100

2,200

2,300

2,400

2,500

2,600

2,700

Gre

en

Stre

ng

th

TSI 32 32 32 32 32

G. S. 2,005 2,229 2,301 2,459 2,673

Volume 91.98% Volume 94.00% Volume 95.20% Volume 97.40% Volume 99.60%

Medium Density/ With Enhancer, Crack Elimination

• FN-0205, .4%lube, .4% enhancer, gear with spokes / hub ~4inch O.D; ~1.75inch height, 7.0 g/cc, driver crack elimination, 98% volume at density

• FC-0208, .4% lube, .25% enhancer,

multi-level part, 2 inches height transition to .5 inches, 7.0 g/cc driver crack elimination, 99% volume at density

Medium Density/ With Enhancer, Crack Elimination

• Proprietary formula, .4% lube, .35% enhancer, large part ~ 6.5 lbs, sprocket 7.0 g/cc crack elimination, 50% reduction in ejection forces, 99% volume at density

• Proprietary formula, .4% lube, .25% enhancer, large 4 level, 5 in. O.D; 2.25 in. high, 2.5 LBS, 7.05 g/cc, crack elimination plus the ability to eject from the die, 99% volume

Processing Problems Addressed with Superlube™/

Enhancer• Dimensional stability

• Die Wear

• Highly effective copper infiltration

• Elimination of blistering on high nickel formulas

Dimensional Stability

• Dimensional Stability - uniform, predictable size change after sintering

• Minimization of density gradients in the part - near hydrostatic conditions

• Particles rearrange during full compaction cycle for best fit - small uniform pores

• Dimensional stability plus superior physical properties; fatigue, strength, hardness

Medium Density, Blistering, Die Wear, Gradient

• FN-0205, .3% lube, .45% enhancer, .7 inch O.D; 1.25 inch height, 7.05 g/cc, driver blistering problems, 98% volume

• 45P base, .4% lube, .35% enhancer, 3inch height, 7.1 g/cc, driver die wear, 99% volume

• 45P base, .4% lube, .25% enhancer, 1.75 inch height, 7.17 g/cc, driver high density/density split minimization, 99% volume

Medium Density, Gradient Infiltration

• FN-0205, .4% lube, .25% enhancer, inside gear ~4inch O.D. ~ 2inch height, 7.1 g/cc ~35 TSI, driver density split, dimensional stability, 98% volume at density

• FLC 4608, .35% lube, gear 1 inch O.D; .65 inch height, 7.2 g/cc, 98.5% volume, copper infiltrated, 7.67g/cc

Conclusions&

Customer Benefits

High Density

• Density better than hot, warm compaction and die wall lubrication

• Superior physical properties

• Elimination of double press / double sinter

• No special equipment or setup required

• Increased process capability

Crack Elimination/ Minimization

• 6.9 - 7.4 g/cc density range• Lower ejection – up to 50%, lower stress on

part• Higher green strength, up to 100%• Near hydrostatic conditions - minimize over

compaction in transition areas• Minimization of gradients• Small uniform porosity• Elimination of micro - cracking

Increased Compressibility

• Compressibility up to 30% higher

• Larger parts in an existing press

• Less stress on tools

• Less wear on tools

• Extended life of press components

Environmentally Friendly

• No metallic Stearates

• Staggered burn out - less gas out at one time

• Pores are not closed - better out gassing - near hydrostatic conditions

• Improved furnace though put

Better Lubrication

• Sliding on film of viscous liquid / verses solid particle

• Tool wear >25% increased life

• Slide forces significantly lower than with conventional solid lubricants – as much as 50%

Predictable

• Lubrication needs are known before going on the press

• Density is calculated before going on the press

• Press tonnage is known before going on the press

• Streamlines the process of quotation, development and problem solving

Final Part

• Physical properties increased 15 - 20%: fatigue, hardness, and strength• Dimensional stability is excellent• Less rejects or scrap• Less chance of surface blemishes• Secondary operations with improved

process capability due to sintered part consistency