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Manganese as a primary alloying element

Manganese as a primary alloying element . Dennis Hammond –Apex Advanced Technologies Richard R. Phillips – Engineered Pressed Materials. Manganese Background. Manganese metal admixed subject to Hydrolysis , oxidation in P/M application

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Manganese as a primary alloying element

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  1. Manganese as a primary alloying element Dennis Hammond –Apex Advanced Technologies Richard R. Phillips – Engineered Pressed Materials

  2. Manganese Background Manganese metal admixed subject to Hydrolysis, oxidation in P/M application Manganese as a pre-alloy, hard to compress, limited use levels Ferro Manganese abrasive, patents Highest performance alloying element- strength, hardenability Previous work demonstrated feasibility of using Manganese metal admixed both as a sinter hardened and case hardened lean formulations

  3. Manganese Background Cont. Manganese as an admix demonstrated feasibility in multiple production furnaces in previous work Manganese coated for protection from hydrolysis and oxidation during blending, storage and handling, supplied as master batch Press conditions developed for maximizing protection during de-lubing and sintering

  4. Key FeaturesAdditive/Lubricant Master Batch Calculations for feasibility of density, desired lubrication, and needed additives Target volume 98.5-99.5% of theoretical at target green density Need for a green compact free of density gradients, semi-hydrostatic Need for excellent lubrication, Apex Superlube® Need for mobile lubricant to achieve best fit of metal particles during compaction and spread of additives

  5. Key FeaturesAdditive/Lubricant Master Batch Need for excellent distribution and dispersion of additives in a segregation free powder mix and compact Protection of reactive additives by coating particles Master batch includes all additives including proprietary additives, pre-mixed and screened, ready to mix with iron powder for easy mixing

  6. Test Matrix for evaluation Fixed Density -7.25g/cc green Fixed Carbon- 0.3% Compressible iron- AT1001HP Mn content- 0%, 0.5%, 0.75%, 1%,1.5%, 2% Sintering- in various production furnaces, conventional gas 2050F, rapid cool 2050F and 2265F, rapid cool vacuum 2265F and 2350F

  7. Test Matrix for evaluation Heat treatment- .6%carbon potential, temper at 350F Test- carbon content, size change, sintered density, TRS strength, hardness, and Impact

  8. Carbon content after Sintering 2050 F slow cool

  9. Conclusions- Carbon loss Less losses of Graphite with Manganese than with plain iron Manganese well protected using this coating technology

  10. Conclusions- density and size Higher sintering temperature results in higher sintered density Increased Mn leads to increased growth Sintering1% Mn at 2265F/1240C appears optimum for density 0.75 to1% Mn gives near neutral growth <0.1% change considered to be ideal

  11. Conclusions –TRS Strength 0.75% Mn appears to be optimum for TRS Near 100% improvement in strength at higher temperatures over 2050F/1121C Heat treated 0.5% Mn gives optimum results

  12. Conclusions- hardness As sintered general improvement in hardness with increased Mn content Hardness after heat treatment no significant improvement after 0.75% Mn Hardness after heat treatment with 0.75% Mn all 44 HRC and above

  13. Conclusions -Impact 0.5% -0.75% Mn optimum for impact Fast cooling gas furnace gave the best impact Mn coupled with higher temperature sintering can give dramatic improvements of impact strength

  14. Over all conclusions Elemental Mn can be protected and effectively used in powdered metal No significant carbon loss No compromise of compressibility Properties can generally be improved with Mn levels of 0.5 to 1% Increased sintering temperature gives improved properties with Mn containing formulas

  15. Over all conclusions, Cont. Mn can be a cost effective alloying element Mn can be used in powdered metal on convention sintering furnaces Mn can be substituted for other more costly alloying elements

  16. Acknowledgments Horizon, Ridgway Powder Metals, Engineered Pressed Materials, Advantage Metal Powders, Product Assurance

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