Apex Advanced Technologies, Inc. Presented by: Dennis Hammond Contributor Richard Phillips

1. 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

2. Presentation Outline • Overview of Superlube™, key characteristics • Overview of Enhancer and use • Cracks/improved compactabilty • Other processing problems • Conclusions

3. 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

4. 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%

5. 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

6. 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

7. 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

8. 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

9. Cracks Root Causes • Improper material composition • Interparticle side shifting action • Improper elastic strain release • High tensile/shear stress

10. 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

11. 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

14. 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

15. 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

18. 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

19. 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

20. Processing Problems Addressed with Superlube™/ Enhancer • Dimensional stability • Die Wear • Highly effective copper infiltration • Elimination of blistering on high nickel formulas

21. 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

22. 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

23. 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

24. Conclusions&Customer Benefits

25. 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

26. 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

27. 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

28. 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

29. 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%

30. 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

31. 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