Near Full Density As Sintered Powdered Metal (P/M) Parts Produced From Water Atomized Powder With Properties Comparable

1. Near Full Density As Sintered Powdered Metal (P/M) Parts Produced From Water Atomized Powder With Properties Comparable To Wrought Steel Richard R. Phillips - Engineered Pressed Materials Dennis Hammond - APEX Advanced Technologies, LLC

2. Key Features of the Technology Water atomized powder Low alloy steel -100 mesh >99.5% theoretical density Properties comparable or superior to wrought steel Standard tooling/ conventional pressing Normal compaction range

3. Key Features of the Technology Continued • High temperature sintering < 2500F (atmospheric or vacuum) • Conventional steel heat treating • Post heat treating operations similar to wrought processing

4. Lubricant Requirements For Near Full Density P/M Parts • Increase green density • Mobility of the lubricant • Effective removal of the lubricant • Excellent dimensional stability

5. High Green Density with Standard Equipment • Reduced level of lubricant, typical use level .25%-.4% • Green Densities 7.2-7.4 g/cc typical for common formulas • Micro cracking and delamination eliminated • Green density increased due to reduced volume of lubricant and better fit of particles resulting from mobility of the lubricant • Lubricant is more effective

6. Mobility of Lubricant • Lubricant transforms with shear, pressure, and friction from a solid to a viscous liquid at relatively low pressure (~ 4 tsi with shear) • Mobility allows for effective rearrangement of metal particles • Mobility allows for lubricant to be forced to the die wall as well as hydrostatic environment within the compact

7. Effective Removal of the Lubricant • Environmentally friendly,contains no metal • Staggered decomposition rate • Up to 70% less gas trying to exit the part at peak decomposition relative to conventional lubricants • Elimination of cracking and blistering with high nickel formulas • Elimination of recondensation of lubricant on part surfaces

8. Excellent Dimensional Stability • No micro cracks or delamination • Small uniform pore size in the green state • No unplanned density gradients in the part • Relatively stress free green part • Density split eliminated • Uniform, predictable shrinkage • Enhanced sintering efficiency

9. Other Part Attributes • Good surface finish • Good ejection with reduced level of lubricant • Due to the high green densities achieved, excellent green strength is also obtained

10. Density Gradient – Shape Retention

11. Density Gradient – Shape Retention

12. Pressure/Density Curve FLN-0706

13. Materials and Processing(Experiments)

14. Test Alloys • Hoeganaes Ancorsteel 85HP and 150HP formulated to provide a resulting alloy with 0.56%Carbon and Nickel contents between 2 and 6.6%. • Pressed at 276 (20),414 (30), 552 (40) ,690 (50), and 828 (60) MPa (TSI). • Vacuum or Atmosphere High Temperature Sintering • Heat Treated to Commercial Wrought Steel Properties

15. Tensile Data

16. Comparison to Wrought Tensile Data

17. Comparison to Wrought Tensile Data

18. Comparison to Wrought Tensile Data

19. Charpy Impact Comparison

20. Size Change/Coefficient of Variance Coefficient of Dimensional Variance (%) Equal to the standard deviation divided by the average multiplied by 100 Pressed Direction 0.17% Perpendicular to Pressed Direction 0.084%

21. Cylinders Back row in the as-molded condition. Front row in sintered and heated condition. OD = 1.880” , OAL = 1.755”, 1.500”, 0.750”, 0.500”

22. Processed Samples Samples in molded, sintered and heat treated, and machined condition. (7.81 g/cc, 45 HRC)

23. Gears, Pawls and Rollers Back row in the as-molded condition. Front row in sintered and heated condition.

24. Density 7.84 g/cc (>99.5% Theoretical Density) 7.41 g/cc (95% Theoretical Density) 6.70 g/cc (85% Theoretical Density)

25. Future Analysis (Fatigue) Stress Endurance values for various sets of process conditions

26. P/M and Other Process Costs Machining & Precision Casting Powder Forge Double Press & Double Sinter High Velocity Compaction (Double Press – Double Sinter) Relative Cost Single Press & Sinter Warm Compaction High Velocity Compaction ActivatedTM NanotechTM Sinter Density (g/cm3)

27. Conclusions • ANPTM* processing of -100 mesh ferrous powder alloys creates material properties similar to wrought product. • ANPTM utilizes conventional blending, tooling and P/M molding capabilities. • Lubricant choice plays a critical role. • ANPTM is activated during high temperature sintering resulting in densification > 99.5% of theoretical (pore-free). • ANPTM dimensional control is predictable and uniform within < 0.2% variance. ANPTM, ACTIVATEDTM NANOTECHTM are trademarks of Material Technologies, Inc. *Patent Pending

28. Conclusions (cont.) • ANPTM can utilize conventional wrought metal processing to meet specific engineering design requirements to enhance optimum product performance. • Machining without lubricant intrusion. • Plating without impregnation. • Salt Bath Processing • Kolene Nu-tride • Blueing • Ferritic Nitrocarburizing (Atmosphere).

29. Conclusions (cont.) • ANPTM parts can be pressed from 276 (20) to 828 (60) MPa (TSI) and still sinter to full density. • Further development work will result in even greater performance. • Work continuing on a broader selection of alloys.