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NOV.DEC.2010.IJPM cover_July_August IJPM cover 11/29/2010 10:28 AM Page 1
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November/December 2010
46/6
Newsmaker: Herbert Danninger, FAPMI Excellence in Metallography Award Gas-Atomized Iron-Base ODS Alloys Potential Effects of Retained Austenite on End-Quench Cooling Rates 440C Stainless Steels with Improved Hardness and Corrosion Resistance Vacuum Carburizing of Iron–Silicon Alloys
FRONT MATTER_ FRONT MATTER 11/29/2010 10:31 AM Page 15
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FRONT MATTER_ FRONT MATTER 11/29/2010 10:31 AM Page 1
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EDITORIAL REVIEW COMMITTEE P.W. Taubenblat, FAPMI, Chairman I.E. Anderson, FAPMI T. Ando S.G. Caldwell S.C. Deevi D. Dombrowski J.J. Dunkley Z. Fang B.L. Ferguson W. Frazier K. Kulkarni, FAPMI K.S. Kumar T.F. Murphy, FAPMI J.W. Newkirk P.D. Nurthen J.H. Perepezko P.K. Samal D.W. Smith, FAPMI R. Tandon T.A. Tomlin D.T. Whychell, Sr., FAPMI M. Wright, PMT A. Zavaliangos INTERNATIONAL LIAISON COMMITTEE D. Whittaker (UK) Chairman V. Arnhold (Germany) E.C. Barba (Mexico) P. Beiss, FAPMI (Germany) C. Blais (Canada) G.F. Bocchini (Italy) F. Chagnon (Canada) C-L Chu (Taiwan) O. Coube (Europe) H. Danninger, FAPMI (Austria) U. Engström (Sweden) O. Grinder (Sweden) S. Guo (China) F-L Han (China) K.S. Hwang (Taiwan) Y.D. Kim (Korea) G. L’Espérance, FAPMI (Canada) H. Miura (Japan) C.B. Molins (Spain) R.L. Orban (Romania) T.L. Pecanha (Brazil) F. Petzoldt (Germany) G.B. Schaffer (Australia) L. Sigl (Austria) Y. Takeda (Japan) G.S. Upadhyaya (India) Publisher C. James Trombino, CAE
[email protected] Editor-in-Chief Alan Lawley, FAPMI
[email protected] Managing Editor James P. Adams
[email protected] Contributing Editor Peter K. Johnson
[email protected] Advertising Manager Jessica S. Tamasi
[email protected] Copy Editor Donni Magid
[email protected] Production Assistant Dora Schember
[email protected] Graphics Debby Stab
[email protected] President of APMI International Dean Howard, PMT
[email protected] Executive Director/CEO, APMI International C. James Trombino, CAE
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46/6 November/December 2010
Editor’s Note Newsmaker ...Herbert Danninger, FAPMI PMT Spotlight On …Silvio Bartoletti Excellence in Metallography Award Consultants’ Corner John A. Shields, Jr.
RESEARCH & DEVELOPMENT 17 Microstructure Evolution of Gas-Atomized Iron-Base ODS Alloys J.R. Rieken, I.E. Anderson and M.J. Kramer
33 Potential Effects of Retained Austenite on End-Quench Cooling Rates in PM Steels F.J. Semel and D.A. Lados
ENGINEERING & TECHNOLOGY 43 As-Sintered AISI 440C Stainless Steels with Improved Hardness and Corrosion Resistance H. Ovri, C.J. Ohaukwu, K. Bahadirov, M. Larson and P. Kjeldsteen
51 Effect of Silicon on Vacuum-Carburizing Depth of Iron Compacts K. Widanka
56 59 60 61 62 64
DEPARTMENTS PM Industry News in Review Meetings and Conferences APMI Membership Application PM Bookshelf Table of Contents: Volume 46, Numbers 1–6, 2010 Advertisers’ Index Cover: As-HIPed microstructure of CR-144Hf-Y alloy showing residual porosity (dark spots). Photo courtesy Joel Rieken, Iowa State University.
The International Journal of Powder Metallurgy (ISSN No. 0888-7462) is a professional publication serving the scientific and technological needs and interests of the powder metallurgist and the metal powder producing and consuming industries. Advertising carried in the Journal is selected so as to meet these needs and interests. Unrelated advertising cannot be accepted. Published bimonthly by APMI International, 105 College Road East, Princeton, N.J. 08540-6692 USA. Telephone (609) 4527700. Periodical postage paid at Princeton, New Jersey, and at additional mailing offices. Copyright © 2010 by APMI International. Subscription rates to non-members; USA, Canada and Mexico: $100.00 individuals, $230.00 institutions; overseas: additional $40.00 postage; single issues $55.00. Printed in USA. Postmaster send address changes to the International Journal of Powder Metallurgy, 105 College Road East, Princeton, New Jersey 08540 USA USPS#267-120 ADVERTISING INFORMATION Jessica Tamasi, APMI International 105 College Road East, Princeton, New Jersey 08540-6692 USA Tel: (609) 452-7700 • Fax: (609) 987-8523 • E-mail:
[email protected] FRONT MATTER_ FRONT MATTER 11/29/2010 10:31 AM Page 2
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EDITOR’S NOTE
D
oes GEICO save you 15% on car insurance? Is metallography beneficial in identifying the microstructure and chemistry of PM materials? Take a moment to look at the 2010 Grand Prize entry in the Excellence in Metallography competition. Utilizing scanning electron microscopy, energy dispersive spectrography, auger electron spectrography, transmission electron microscopy, and X-ray diffraction, Rieken, Anderson, and Kramer probe the internal structure of gas-atomized oxide-dispersion-strengthened ferritic stainless steels. In combination, these metallographic techniques resulted in a complete and quantitative microstructural characterization of the PM steels down to the nanoscale level. In the “Newsmaker,” Peter Johnson profiles Herbert Danninger, a recipient of the 2010 APMI Fellow Award. A distinguished academic, Herbert has forged strong ties and interactions between the academic community and the PM industry in Europe. Returning to the “Consultants’ Corner,” John Shields provides detailed responses to two questions related to ferrous PM. The first elaborates on what is meant by “2 w/o max. other” in most MPIF materials, and the second discusses and compares intergranular embrittlement in wrought and PM steels of similar composition and hardness. In the “Research & Development” section, Rieken et al. detail the production of iron-base ODS alloys by means of gas-atomization reaction synthesis. After consolidation, a uniform distribution of nanoscale yttriumenriched oxide dispersoids is achieved throughout the microstructure. Also in this section, Semel and Lados employ process modeling simulations to predict the likely effect of porosity on retained austenite and end-quench cooling rates in PM steels. In the first of two contributions to the “Engineering & Technology” section, Ovri et al. describe the results of a study to develop as-sintered 440C stainless steels with enhanced hardness and corrosion resistance. The compositions and sintering temperatures are identified to give optimum combinations of the as-sintered properties. This section is completed with a paper by Widanka that quantifies the role of silicon on the vacuum carburizing of iron. Silicon additions up to 1 w/o increase the carburized depth by ~35% compared with iron in the absence of silicon.
Alan Lawley Editor-in-Chief
Subterfuge! That’s my take on the 2010 Nobel Prizes in Physics and Chemistry. While in no way diminishing the brilliance of the work resulting in each award, both clearly reflect achievements in Materials Science & Engineering utilizing basic tenets of Physics and Chemistry. The Physics Prize acknowledges two Russian-born scientists for creating graphene, a transparent two-dimensional form of carbon only one atom thick but more than 100 times stronger than steel, with unique properties: electrical conductivity similar to that of copper, and thermal conductivity better than that of other materials. Envisaged applications include computer chips, pollution monitoring, and improved flat-screen televisions. An American and two Japanese researchers received the Nobel Prize in Chemistry for their work in developing new and more efficient ways to link carbon atoms together in order to build complex molecules. This approach is a vital step in developing novel medicines, materials such as polymers and electronics. Both advances illustrate innovation manipulation of the relations between processing, internal architecture (microstructure), and properties, a cardinal tenet of Materials Science & Engineering.
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Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
FRONT MATTER_ FRONT MATTER 11/29/2010 10:31 AM Page 3
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Stain Free Solutions for PM Components The leading producer of metal powders, North American Höganäs, has introduced a series of products that address an increasingly problematic issue in component manufacturing: Stains. By the way, these products also facilitiate improved lubrication, enhanced machinability, increased productivity and scrap reduction.
SM3 t Stain Free Superior machinability t Improved machinability additive t No detrimental effect on mechanical properties or corrosion resistance ® Starmix Boost t Stain Free High performance t Improved ejection properties bonded mix t Excellent fill characteristics t Stain Free Intralube® E Advanced lubricant t Improved lubrication properties t Zinc free
www.nah.com
NEWSMAKER_ NEWSMAKER 11/29/2010 10:33 AM Page 4
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NEWSMAKER
HERBERT DANNINGER, FAPMI
By Peter K. Johnson*
Herbert Danninger, professor and managing director of the Institute of Chemical Technologies and Analytics, Vienna University of Technology (TUW), is a vocal advocate for stronger ties between the academic community and industry. In his teaching and research he has pursued the practical side of science to solve industrial problems. A recipient of the APMI International Fellow Award in 2010, he shares his views on PM technology issues. “My research work was and is carried out in part in close cooperation with industrial enterprises,” he says. These represent many aspects of PM processing, from leading metal powder makers and tool-steel producers to hardmetal suppliers and PM parts fabricators. He sees the need to convince PM parts customers that better properties cost more. “You cannot expect better performance with cheaper materials,” he stresses. Since receiving his Doctor of Technical Sciences (Dr. techn.) degree in 1980 from the TUW, Danninger has earned international recognition for his many accomplishments. His honors include the TUW Dr. Ernst Fehrer Prize for the development of liquid-phase-activated gravity sintering of stainless steels, the Skaupy Lecture award from the German Gemeinschaftsausschuss Pulvermetallurgie, and Doctor Honoris Causa of the Universitatea Tehnica din Cluj-Napoca in Romania. He has published more than 320 scientific papers in journals and conference proceedings and has given numerous oral presentations at international conferences, foreign universities, and institutes. Danninger’s interest in PM was cultivated while studying under Professor Gerhard Jangg, a prominent European powder metallurgist who had close links to PM companies. “Professor Jangg always *Contributing editor
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told us that you have to think using the brains of industry and anticipate the needs of companies before they recognize them,” he recalls. Danninger says he was also influenced by a book on refractory metals authored by Jangg, Richard Kieffer, and Peter Ettmayer. “Their style of writing was fascinating,” he says. “They described how temperamental these metals are.” He went on to write his doctoral thesis on “The Influence of Manufacturing Parameters on the Properties of Tungsten Heavy Alloys.” His teaching responsibilities encompass a basic class in inorganic chemical materials numbering 120–130 diploma engineering students, materials technology courses for Master’s degree students, and supervising Master’s and PhD thesis projects. About 40 percent of his time is devoted to teaching. A strong proponent of high-temperature sintering (>1,200ºC) since the early 1980s, Danninger says most European PM companies are devoting more development time to the process. His work points to the crucial importance of chemical reactions in the early stages of sintering by switching to oxygensensitive elements such as chromium, manganese, silicon, and vanadium. “These reactions remove surface oxides and, for standard constituents such as iron, molybdenum, and nickel, are ‘free of charge’ by occurring at temperatures below the standard sintering temperature. For chromium or manganese, the reduction temperatures are in the same order as belt-furnace sintering temperatures; therefore, high-temperature sintering is decidedly beneficial here,” he stresses. He refutes the adage that sintering destroys precision and cites the shrinkage controls used in metal injection molding (MIM). “You must choose sintering routes that minimize distortion,” he adds. ijpm
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
NEWSMAKER_ NEWSMAKER 11/29/2010 10:33 AM Page 5
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NEWSMAKER: HERBERT DANNINGER
His sintering research has included liquid-phase sintering and related homogenization and pore-formation processes. Chemical reactions during sintering and heat-treatment processes are other areas of study. He has also devoted serious time to investigating the fatigue behavior of PM steels and tooling materials. His research with an industrial partner underscores the importance of fatigue testing with high loading cycles ranging from more than 100 × 106 cycles up to 109 cycles, he reports. “The old concepts of selling PM’s shape and precision are not
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
sufficient,” he stresses. “You must offer increased performance, especially fatigue properties.” New alloys and the combination of high-temperature sintering and warm compaction can also offer improved properties. He believes that new material systems are needed because, in his opinion, the traditional iron–copper–carbon system has reached a plateau in performance. Danninger is confident about PM’s future and believes there is still much work to be done. “There is not a lack of ideas,” he says, “but rather a lack of time and funds.” ijpm
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NEWSMAKER_ NEWSMAKER 11/29/2010 10:33 AM Page 6
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THE POWDER EXPERTS ‘One stop’ supply source for all your powder needs HC FeMn • LC Si Mn • Si Mn • MC FeMn Se Free Mn Metal • HC FeCr • LC Fe Cr • Cr Metal Fe Si • Fe Si Zr • Fe Ti • Cr C • Fe B • Fe Mo and many more powders Available from our plants in Mexico • United States • Turkey
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SPOTLIGHT ON_ SPOTLIGHT ON 11/29/2010 10:34 AM Page 7
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SPOTLIGHT ON ...
SILVIO BARTOLETTI, PMT Education: Degrees in Industrial Chemistry, Colégio Oswaldo Cruz, São Paulo, 1965; Mechanical Engineering, Universidade Braz Cubas, São Paulo, 1974; Production Administration, Fundação Getulio Vargas, São Paulo, 1998 Why did you study powder metallurgy/particulate materials? My first contact with the powder metallurgy (PM) was in mid-1970 when I worked for a large householdappliance business; until then I knew nothing about PM. What caught my attention were self-lubricating bushings that were, and are still, used to replace bearings requiring lubrication. When I started my activities at Metalpó, I began to understand how a self-lubricating bushing works and why it is self-lubricating. One of the main reasons that led me to study PM technology more deeply was the diversity of applications of products made from metal powders, and the wide spectrum of materials available in the marketplace targeted at various applications, depending on the mechanical and metallurgical requirements. What was your first job in PM? What did you do? The Metalpó/Combustol group is made up of companies that focus on equipment for steel mills, petrochemicals, and organic-waste processing, among others. The group also has a refractories department, heat treatment, and PM. I started my PM career in 1974 working primarily in setting up the quality control department. After a brief stay I moved to the plant that made electrolytic copper powder. Here I was creating copper powders with densities between 1.0 and 2.7 g/cm3. At that time, all the bronze parts manufactured by Metalpó used electrolytic copper powder as the raw material. Besides copper powder, I developed red copper oxide (Cu2O), used as a raw material in manufacturing paints for seagoing vessels, and black copper oxide (CuO) for agricultural and other applications.
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
Manufacturing tin powder by air atomization was also one of the improved techniques for obtaining density and size distributions within more accurate specifications. Controlling metal powder manufacturing process parameters, such as hydrogen loss (oxygen content), particle size, specific surface area, and average particle diameter, were also a part of my early work in PM. Describe your career path and companies worked for, and responsibilities. I started my career in industry in 1965 after I received my degree in industrial chemistry, working for a company in the Pirelli Group for four years. My first function was as a production scheduler, after which I was promoted to work in a testing laboratory for electric cables. In 1969 I transferred to ARNO S/A, a large company that is now part of the French group SEB. The company dealt in automotive products for the Delco Remy line, home appliances, and industrial motors. I served as an appliance assembly-line coordinator, and it was here that I had my first encounter with PM parts used in motors for household fans, food blenders, mixers, and other small appliances. In 1974 I began my career at Metalpó. My first job was setting up the quality department. In 1978 I took part in the building of a facility for water atomization of nonferrous powders, a technology acquired from a French company. I managed the factory until 2004. In 1986 I took over the management of Metalpó’s industrial area which encompassed the production of parts, Manager Metalpó Industria e Comercio Ltda. Rua Cel. Jose Rufino Freire 453-A Pirituba São Paulo, SP CEP 05159-900 Brazil Phone: 55-11-39047690 Fax: 55-11-39063173 E-mail:
[email protected] 7
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SPOTLIGHT ON ...SILVIO BARTOLETTI, PMT
metal powders, tooling, and maintenance. I carried out this function until 2008. Today I am an engineering manager with primary responsibilities in new product development, the application of new technologies, ISO-TS specifications, tooling design, and tool fabrication. What gives you the most satisfaction in your career? Without doubt, it is the variety of tasks and challenges throughout my career and constant technological improvement due to knowledge of new materials that keep me motivated in the performance of my job. It is difficult to highlight any one reason for my satisfaction, but the details of making powder via electrolysis and water or air atomization have been a highlight, since they occurred at the start of my technical training in PM. What major changes/trend(s) in the PM industry have you seen? PM has developed significantly and is increasingly expanding its markets, especially in the automotive industry. I have witnessed the development of new materials and processes to achieve high densities and enhanced mechanical properties with increasing dimensional stability. Some of the materials and processes are high-compressibility and high-hardenability powders, special lubricants, warm die compaction, and sinter hardening. Another important segment of PM is that of soft magnetic composite materials for electromagnetic applications. They provide important benefits in reducing engine weight and cost, while maintaining strength due to new design concepts. These are therefore sustainable solutions from an ecological point of view, which could enable a change from the internal combustion engine to electric or hybrid vehicles. My team and I have developed a product with this material that is being used in fuel injectors. Metal injection molding is another trend, com-
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bining features of PM with plastic injection molding, capable of producing parts of complex geometry with the benefits of PM, namely, precision, near-net shaping, high productivity, and low cost. Why did you choose to pursue PMT certification? It is difficult for anyone to do a self-evaluation of our knowledge of PM. I believe the PMT examination embraces questions that reflect the knowledge that professionals must have. I find the diversity of technologies covered in the survey interesting, dealing with raw materials, applications, technologies, designs, and so on. I was honored and pleased when I received the news of my certification, which motivated me to continue to keep abreast of new materials and applications. How have you benefited from PMT certification in your career? Recognition by Metalpó senior management of my accomplishment was immediate. I received compliments, which keep me motivated to continue to improve technically. I hope to continue my career, and whenever possible, attend national and international events related to PM. What are your current interests, hobbies, and activities outside of work? I like to entertain relatives and friends at my house on weekends. One of my pastimes is to be in the kitchen preparing my favorite Italian dishes. I enjoy the beach, and I go whenever I have the opportunity. Once in a while I visit a home for the elderly or for children and provide support. As we are in a country where football (soccer) is a major sport, and as I am no different from most Brazilians, I like a good football game, occasionally live at a stadium but most often at home on TV. ijpm
Would you like to be featured here? Have you been PMT Certified for more than 2 years? Contact Dora Schember (
[email protected]) for more information.
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
Metallography Award_Zheng et al 11/29/2010 10:36 AM Page 9
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2010 EXCELLENCE IN METALLOGRAPHY AWARD
GRAND PRIZE
GAS-ATOMIZED CHEMICAL RESERVOIR ODS FERRITIC STAINLESS STEELS Joel R. Rieken*, Iver E. Anderson, FAPMI**, and Matthew J. Kramer***
ABSTRACT Gas-atomization reaction synthesis was used to surface oxidize ferritic stainless steel powders resulting in an ultrathin (1 w/o than in those with a silicon content 1 w/o Si. REFERENCES 1. Binary Alloy Phase Diagrams, Second Edition, 1990, ASM International, Materials Park, OH. 2. P. Beiss, R. Ruthardt and H. Warlimont, Powder Metallurgy Data, Landolt-Börnstein Online, Springer Berlin Heidelberg, Germany, 2003, vol. 2A1.
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
Widanka_Zheng et al 11/29/2010 10:46 AM Page 55
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EFFECT OF SILICON ON VACUUM-CARBURIZING DEPTH OF IRON COMPACTS
3. D.H. Herring and P.T. Hansen, “Heat Treating Ferrous P/M Parts”, Advanced Materials & Processes, 1998, vol. 153, no. 4, pp. 44CC–44GG. 4. D.H. Herring and J. St. Pierre, “Vacuum Carburizing of P/M Steels”, Progress in Powder Metallurgy 1987, compiled by C.L. Freeby and H. Hjorth, Metal Powder Industries Federation, Princeton, NJ., 1987, vol. 43, pp. 525–537. 5. R.G. Weber, “Vacuum Carburizing and Carbonitriding of Powder Metallurgy Ferrous Alloys”, Powder Metall. Intl.,
1983, vol. 15, no. 2, pp. 94–97. 6. D.H. Herring, “Pros and Cons of Atmosphere and Vacuum Carburizing”, Industrial Heating, 2002, vol. 69, no. 1, p. 45. 7. F. Preisser, R. Seemann and W.R. Zenker, “Update on Vacuum-Based Carburizing”, Advanced Materials & Processes, 1998, vol. 153, no. 6, pp. 84ll–84LL. 8. V. Raghavan, “The Carbon-Iron-Silicon System”, J. Alloy Phase Diagram, 1986, India, vol. 2 no. 2, pp. 97–107. ijpm
WANTED: USED HIGH TEMPERATURE FURNACE Used high temperature furnace wanted having the following specifications: 2400° - 2600° Fahrenheit or higher pusher furnace, with hydrogen and nitrogen protective atmospheres; ideally capable of running 12” x 12” x 1” ceramic pusher plate design; requires 4” - 6” of working height; will consider all sizes and manufacturers. Contact-Robert Henkle at (414) 298-8140 or at
[email protected] Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
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58-64,C3,C4_MEETINGS_CONFERENCES 11/29/2010 10:49 AM Page 56
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PM INDUSTRY NEWS IN REVIEW The following items have appeared in PM Newsbytes since the previous issue of the Journal. To read a fuller treatment of any of these items, go to www.apmiinternational.org, login to the “Members Only” section, and click on “Expanded Stories from PM Newsbytes.”
Nonferrous Powder Plant Unaffected by Zinc Refinery Shutdown Horsehead Corporation’s metal powder plant in Palmerton, Pa., continues operating at a high level and is not impacted by the temporary shutdown of the company’s Monaca, Pa., zinc oxide and metal refinery. Horsehead makes airatomized zinc, brass, copper, phos-copper, and nickel silver powders and infiltrants in Palmerton.
Miba Gains, Acquires Friction Business Miba AG, Laarkirchen, Austria, reports a 36.8 percent rise in sales for the first half of its fiscal 2010–11 year to 203.1 million euros (about $265 million). All business segments scored robust incoming orders. Continuing its expansion path, Miba also reports the acquisition of the HOERBIGER Group’s off-road vehicle friction lining business in Schongau, Germany.
Coatings Company Sells 41 Percent Interest Abakan Inc., a Miami, Floridabased development company, will acquire a 41% interest in Powdermet, Inc., Euclid, Ohio. The stock purchase agreement covers an initial payment of $500,000 with a closing on or before September 30 for the remaining portion of the price.
Joint Venture for Electric Car Battery Materials Formed H.C. Starck GmbH, Goslar, Germany, will form a joint venture company, CS Energy Materials, with Chisso Corporation in Japan to develop and make lithium mixed oxides for high-performance lithium-ion batteries for electric cars. Starck will have a 49 percent interest in the new company and Chisso 51 percent.
Silicon Carbide and Silicon Nitride Powder Agreement H.C. Starck Ceramics, a subsidiary of H.C. Starck GmbH & Co. KG, Goslar, Germany, announces a new cooperation agreement with Krahn Chemie, a distributor in Hamburg, Germany, covering the European sales of alpha-silicon carbide and silicon nitride powders mixed with sintering additives and pressing agents. The products, used in high-performance ceramics and as pressready materials, are marketed under the trade names Starceram S (α-SiC) and Starceram N (Si3N4).
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Ecka Granules Group Selects Buyer The insolvency administrators of the Ecka Granules Group, Fürth, Germany, have signed a definitive agreement selling substantially all of the company to Platinum Equity LLC, Los Angeles, Calif., owner of SCM Metal Products, industry sources report. Although details of the acquisition were not released, completion of the transaction is expected in the fourth quarter pending customary closing conditions.
Microwave Marketing Agreement Spheric Technologies, Inc., Phoenix, Ariz., and Victec Europe Limited, Befordshire, England, have signed an international cooperative marketing agreement to develop microwave technology, equipment, and applications. Each firm has exclusive territorial rights for the sale of microwave furnaces built by Synotherm Corp. Drexel Researchers Receive Major Grant for Battery Anode Materials The U.S. Department of Energy (DOE) has awarded a $1 million grant to Yury Gogotsi, Trustee Chair Professor, and Michael Barsoum, A.W. Grosvenor Professor, Department of Materials Science & Engineering, Drexel University, to develop novel battery anode materials. The grant is from the DOE Batteries for Advanced Transportation Technologies program aimed at increasing the performance and decreasing the cost of batteries for plug-in electric and hybrid electric vehicles. North American Overview Report at World Congress The North American powder metallurgy industry’s strong rebound continued into the summer of 2010, reported MPIF President Michael E. Lutheran in his comments at the Global Review session at the PM2010 World Congress in Florence, Italy. Iron
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PM INDUSTRY NEWS IN REVIEW
powder shipments soared 62 percent to 240,000 short tons through August and copper and copper-base powder shipments rose 38 percent to almost 8,000 short tons for the first six months. DOE Awards $2.8 Million for Demonstration Industrial Fuel Cell Fuel Cell Energy, Inc., Danbury, Conn., with partner ACuPowder International, LLC, Union, N.J., have been awarded $2.8 million Department of Energy funding to demonstrate a combined power & heat fuel cell for industrial applications. The two firms will jointly develop and demonstrate the efficient use of a 300kw DFC300 fuel cell at the ACuPowder facility by utilization of clean electricity, hydrogen (co-produced by the unit), and usable highquality heat. PM Titanium Project Aimed at Increasing Dehumidifying Performance ADMA Products Inc., Hudson, Ohio, has received a $4.4 million award from the U.S. Department of Energy to develop a high-efficiency online membrane air dehumidifier for enabling sensible cooling in warm and humid climates. Serving as team leader for the three-year project, ADMA will work with the Pacific Northwest National Laboratory, Richland, Wash. Tungsten Mine Opens with Extended Life North American Tungsten Corporation Ltd. reports an increase of the probable mineral reserve at its Cantung Mine to 1.693 million tons, which extends the mine life to more than four years at its current Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
mill capacity. The mine is scheduled to begin operating again during October. Sandvik, Carpenter Establish Powder Technology Partnership Carpenter Technology and Sandvik Materials Technology have announced the formation of a strategic partnership that, according to the partners, will result in the creation of an integrated value chain from R&D and powder production to sales and application development for near-net-shape solutions. Under the agreement Sandvik has acquired a 40 percent share in Carpenter Powder Products AB, Torshälla, Sweden, while Carpenter has acquired a 40 percent share in Sandvik Powdermet AB, Surahammar, Sweden. Sodium-Doped Sputtering Targets The efficiency of CIS/CIGS (copper–indium–selenium/copper–in dium–gallium–selenide) solar cells can be significantly improved by sputtering a precisely controlled layer of sodium-doped molybdenum, according to a report by Plansee AG, Reutte, Austria. The company offers MoNa sputtering targets with full density, high purity, and a uniform fine-grain structure. Powder Maker Reports Record Third Quarter Swedish powder maker Höganäs AB reports its best third-quarter sales ever, MSEK 1,728 (about $258 million), a 45 percent increase over 2009. Net sales for the first nine months jumped 58 percent to MSEK 5,059 (about $755 million).
Carbide Joint Venture Established After signing a joint-venture agreement on October 1 with CB Carbide, Taiwan, Plansee’s CERATIZIT Group, Luxembourg, owns a 50 percent stake in one of Asia’s leading carbide manufacturers with eight production locations in Taiwan and China. The agreement will increase the Plansee division’s sales in Asia by 25 percent. GKN Automotive Unit Gains The Automotive unit of GKN plc, London, UK, which includes its Driveline and Powder Metallurgy businesses, posts 2010 thirdquarter sales of £800 million (about $1.28 billion), a 34 percent gain from 2009. The company reports PM’s trading margin at 7.9 percent. New Furnace Installed Surface Combustion, Inc., Maumee, Ohio, reports the installation of a new Allcase Batch Integral Quench furnace line at Bluewater Thermal Solutions’ plant in Greensburg, Ind. The furnace line includes two furnaces with atmosphere top-cool and oil-quench capabilities, two temper furnaces, an endothermic gas generator, a spray/dunk washer, and companion equipment. MIM Feedstock Maker Upgrades Web Site Advanced Metalworking Practices (AMP), LLC, Carmel, Ind., has redesigned its Web site adding new information on ADVAMET® feedstock for metal injection molding. The new site also includes AMP’s ISO 90012008 certification and feedstock material data sheets.
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PM INDUSTRY NEWS IN REVIEW
Thorium-Free TIG Welding Electrodes PLANSEE, Reutte, Austria, reports that customers are switching to thorium-free tungsten welding electrodes to avoid health and handling risks associated with thorium, a weakly radioactive element. A thoriumfree electrode, such as the lanthanum-containing WL15 product, is a recommended alternative providing improved ignition properties and wear resistance, notes the company.
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Hoeganaes Expands in China Hoeganaes Corporation, Cinnaminson, N.J., has opened a metal powder premixing and market-support facility near Shanghai in Danyang, Jiangsu Province, China. Serving Chinese customers with quick delivery of press-ready premixes, the new facility also includes a laboratory with technical support and qualityassurance services, and warehousing for the company’s full range of ferrous powder products.
New Workhorse Attritor Union Process, Inc., Akron, Ohio, has introduced the C-20 attritor for applications requiring continuous production of large amounts of materials such as ceramics, coatings, and metal oxides. Labeled a ‘workhorse’ machine, it uses 1/8-3/8 inch grinding media. ijpm
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
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MEETINGS AND CONFERENCES
2011 MIM2011 INTERNATIONAL CONFERENCE ON INJECTION MOLDING OF METALS, CERAMICS AND CARBIDES March 14–16 Lake Buena Vista (Orlando), FL MPIF* (NOTE: NEW DATES & LOCATION) PowderMet2011: MPIF/APMI INTERNATIONAL CONFERENCE ON POWDER METALLURGY & PARTICULATE MATERIALS May 18–21 San Francisco, CA MPIF* INTERNATIONAL CONFERENCE ON TUNGSTEN, REFRACTORY & HARDMATERIALS VIII Co-located with PowderMet2011 May 18–21 San Francisco, CA MPIF* ICM11 THE 11TH INTERNATIONAL CONFERENCE ON THE MECHANICAL BEHAVIOR OF MATERIALS June 5–8 Lake Como, Italy www.icm11.org TI – 2011 12TH WORLD CONFERENCE ON TITANIUM June 19–25 Beijing, China http://www.ti-2011.com/
BASIC PM SHORT COURSE July MPIF* 7TH INTERNATIONAL SYMPOSIUM ON RHENIUM AND TECHNETIUM July 4–8 Moscow, Russia
[email protected] THERMEC 2011 7TH INTERNATIONAL CONFERENCE ON PROCESSING & MANUFACTURING OF ADVANCED MATERIALS August 1–5 Quebec City, Canada www.thermec2011.ca/ INTERNATIONAL CONFERENCE ON SINTERING 2011 August 28–September 1 Jeju Island, Korea www.sintering2011.org PM MACHINABILITY SEMINAR September MPIF* ILASS 2011 24TH EUROPEAN CONFERENCE ON LIQUID ATOMIZATION AND SPRAY SYSTEMS September 5–7 Estoril, Portugal www.ilass2011.org PM COMPACTING/TOOLING SEMINAR November MPIF*
2012 PowderMet2012: MPIF/APMI INTERNATIONAL CONFERENCE ON POWDER METALLURGY & PARTICULATE MATERIALS June 10–13 Nashville, TN MPIF* SUPERALLOYS 2012: TWELFTH INTERNATIONAL SYMPOSIUM ON SUPERALLOYS September 9–13 Champion, PA PM2012 YOKOHAMA POWDER METALLURGY WORLD CONGRESS & EXHIBITION October 14–18 Yokohama, Japan www.pm2012.jp/
2013 PowderMet2013: MPIF/APMI INTERNATIONAL CONFERENCE ON POWDER METALLURGY & PARTICULATE MATERIALS June 23–26 Chicago, IL MPIF*
2014 PM2014 WORLD CONGRESS May 18–22 Orlando, FL MPIF*
*Metal Powder Industries Federation 105 College Road East, Princeton, New Jersey 08540-6692 USA (609) 452-7700 Fax (609) 987-8523 Visit www.mpif.org for updates and registration. Dates and locations may change Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
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MEMBERSHIP APPLICATION Please type or print legibly.
I hereby apply for membership in APMI International. Name (First, Middle Initial, Last) Company
ANNUAL DUES: G United States, Canada and Mexico .............$105.00 G Overseas.......................................................$125.00 G Students (Full-Time Only)..................................$25.00 G Overseas Students (Full-Time Only) ..................$40.00 Payments by check or credit card are acceptable, in US Dollars, drawn on a US bank. Make check payable to APMI International. Upon receipt of full payment, membership will be processed.
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PLEASE CHECK APPROPRIATE BOX Level of Education G High School G Associate Degree G Some College G Bachelor’s Degree
G Master’s Degree G PhD
PLEASE CIRCLE APPROPRIATE NUMBERS (ONLY ONE IN EACH CATEGORY) Primary Job Function Company Primary Function 1 Company Management 1 PM Parts Manufacturer 2 Research & Development 2 Metal Powder Supplier 3 Engineering (incl. Design) 3 User of PM Parts or Products 4 Sales/Marketing 4 Equipment Mfg/Supplier (i.e., presses, furnaces, lab equip., 5 Metallurgical/Laboratory belts, atmospheres, services, etc.) 6 Production/Mfg/Maintenance 5 Consulting or Research 7 Technician 6 Educational Institution 8 Educator 7 MIM—Parts and Suppliers 9 Student 8 HIP/Advanced Particulate Products 10 Human Resources 9 Hardmetals 11 Accounting/IT 10 Other ______________________________ 12 Quality Assurance 13 Other ______________________________ APMI International 105 College Road East, Princeton, New Jersey 08540-6692 USA Phone: 609-452-7700 Fax: 609-987-8523
[email protected] For a complete list of benefits and an online application visit: www.apmiinternational.org
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PM BOOKSHELF
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
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YEARLY CONTENTS INTERNATIONAL JOURNAL OF POWDER METALLURGY TABLE OF CONTENTS FOR VOLUME 46, NUMBERS 1–6, 2010
46/1 JANUARY/ FEBRUARY 2010 2 Editor’s Note 4 Consultants’ Corner Kenneth J.A. Brookes HEALTH & ENVIRONMENT 9 Update on REACH, the CLP Regulation, and Their Implementation in the European Union PM Industry O. Coube and P. Brewin RESEARCH & DEVELOPMENT 17 Optimization of Compressibility and Hardenability by Admixing and Prealloying N. Giguere and C. Blais ENGINEERING & TECHNOLOGY 31 Effect of Sintering Temperature on Static and Dynamic Properties of Sinter-Hardened PM Steels F. Chagnon OUTSTANDING TECHNICAL PAPER: PowderMet2009 43 Influence of Chemical Composition and Austenitizing Temperature on Hardenability of PM Steels P.K. Sokolowski and B.A. Lindsley DEPARTMENTS 55 PM Industry News in Review 56 Web Site Directory 64 Advertisers’ Index
46/2 MARCH/APRIL 2010 2 4 9 11
15 21
29 39
45 46 47 48
27 37
49
61
73 75 76 78 79 80
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FOCUS: Microminiature Powder Injection Molding— Part II Full-Density Nanopowder Agglomerate Sintering of Injection Molded Iron–Nickel J.-S. Lee, B.-H. Cha and W.-K. You A Review of Computer Simulations in Powder Injection Molding S.J. Park, S. Ahn, T.G. Kang, S.-T. Chung, Y.-S. Kwon, S.H. Chung, S.-G. Kim, S. Kim, S.V. Atre, S. Lee and R.M. German Characterization and Simulation of Macroscale Mold-Filling Defects in Microminiature Powder Injection Molding S.G. Laddha, C. Wu, S.-J. Park, S. Lee, S. Ahn, R.M. German and S.V. Atre Sintering of Powder Injection Molded 316L Stainless Steel: Experimental Investigation and Simulation X. Kong, T. Barriere, J.C. Gelin and C. Quinard DEPARTMENTS PM Industry News in Review Meetings and Conferences Instructions for Authors APMI Membership Application PM Bookshelf Advertisers’ Index
FOCUS: Microminiature Powder Injection Molding—Part I Materials for Microminiature Powder Injection Molded Medical and Dental Devices R.M. German Metal and Ceramic Parts Fabricated by Microminiature Powder Injection Molding V. Piotter, T. Hanemann, R. Heldele, M. Mueller, T. Mueller, K. Plewa and A. Ruh High-Strength Powder Injection Molded 316L Stainless Steel L.-H. Cheng and K.-S. Hwang Nitriding Response of Microminiature Powder Injection Molded Titanium T. Osada and H. Miura DEPARTMENTS PM Industry News in Review Meetings and Conferences PM Bookshelf Advertisers’ Index
46/4 JULY/AUGUST 2010
46/3 MAY/JUNE 2010 2 Editor’s Note 5 Consultants’ Corner David Whittaker 9 PM’s New Growth Engine—Technology Development Peter K. Johnson 17 Exhibitor Showcase: PowderMet2010
Editor’s Note Newsmaker Animesh Bose PMT Spotlight On …Todd M. Jensen, PMTII Consultants’ Corner Joseph Tunick Strauss
2 4 6 7 9 11 13
Editor’s Note PMT Spotlight On …Jason R. Forster 2010 APMI Fellow Awards An Appreciation—Alan Lawley Consultants’ Corner Pierre W. Taubenblat 2010 Poster Awards 2010 PM Design Excellence Awards Competition Winners 20 PM World Congress in Florence 22 Axel Madsen/CPMT Scholar Reports ENGINEERING & TECHNOLOGY 25 State of the PM Industry in North America—2010 M.E. Lutheran 29 Industrial Sintering of Hybrid Low-Carbon 3Cr-0.5Mo-xMn Steels M. Selecká and A. Šalak RESEARCH & DEVELOPMENT 43 Solution Annealing and Aging of a MIM CoCrMo Alloy P.V. Muterlle, I. Lonardelli, M. Perina, M. Zendron, R. Bardini and A. Molinari DEPARTMENTS 53 PM Industry News in Review 55 Meetings and Conferences 56 Advertisers’ Index
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YEARLY CONTENTS 46/5 SEPTEMBER/OCTOBER 2010 2 Editor’s Note 4 Newsmaker ...Paul Beiss, FAPMI 7 Consultants’ Corner James G. Marsden, FAPMI FOCUS: PM Titanium 9 Powder Metallurgy Titanium—Challenges and Opportunities Z.Z. Fang 11 Status of Metal Powder Injection Molding of Titanium Randall M. German 19 Review of Titanium-Powder-Production Methods C.G. McCracken, C. Motchenbacher and D.P. Barbis 29 Cold Compaction and Sintering of Titanium and Its Alloys for Near-Net-Shape or Preform Fabrication M. Qian 45 A Critical Review of Mechanical Properties of Powder Metallurgy Titanium H. Wang, Z.Z. Fang and P. Sun 58 61 62 63 64
DEPARTMENTS PM Industry News in Review Meetings and Conferences APMI Membership Application PM Bookshelf Advertisers’ Index
Volume 46, Issue 6, 2010 International Journal of Powder Metallurgy
46/6 NOVEMBER/DECEMBER 2010 2 4 7 9 13
Editor’s Note Newsmaker ...Herbert Danninger, FAPMI PMT Spotlight On …Silvio Bartoletti Excellence in Metallography Award Consultants’ Corner John A. Shields, Jr.
RESEARCH & DEVELOPMENT 17 Microstructure Evolution of Gas-Atomized Iron-Base ODS Alloys J.R. Rieken, I.E. Anderson and M.J. Kramer 33 Potential Effects of Retained Austenite on End-Quench Cooling Rates in PM Steels F.J. Semel and D.A. Lados ENGINEERING & TECHNOLOGY 43 As-Sintered AISI 440C Stainless Steels with Improved Hardness and Corrosion Resistance H. Ovri, C.J. Ohaukwu, K. Bahadirov, M. Larson and P. Kjeldsteen 51 Effect of Silicon on Vacuum-Carburizing Depth of Iron Compacts K. Widanka 56 59 60 61 62 64
DEPARTMENTS PM Industry News in Review Meetings and Conferences APMI Membership Application PM Bookshelf Table of Contents: Volume 46, Numbers 1–6, 2010 Advertisers’ Index
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ADVERTISERS’ INDEX ADVERTISER
FAX
WEB SITE
PAGE
Ace Iron & Metal Co. Inc. ______________(269) 342-0185_____________________________________________________5 ACuPowder International, LLC __________(908) 851-4597 ________www.acupowder.com___________________________49 Ametek Specialty Metal Products _______(724) 225-6622 ________www.ametekmetals.com ________________________16 Asbury Carbons _____________________(908) 537-2908 ________www.asbury.com ______________________________42 Elnik Systems_______________________(973) 239-6066 ________www.elnik.com _______________________________41 Global Titanium _____________________(313) 366-5305 ________www.globaltitanium.com ________________________50 Hascor International Group ____________+10 210 225 6120 _____www.hascor.com _______________________________6 Hoeganaes Corporation _______________(856) 786-2574 ________www.hoeganaes.com______________Inside Front Cover Magnequench_______________________(65) 6415 0670 ________www.mqitechnology.com ________________________15 North American Höganäs Inc. __________(814) 479-2003 ________www.nah.com _________________________________3 Rio Tinto Metal Powders/ Quebec Metal Powders Limited ________(734) 953-0082 ________www.qmp-powders.com _________________Back Cover Robert Henkle ___________________________________________rhenkle@reinhartlaw.com _______________________55 SCM Metal Products, Inc.______________(919) 544-7996 ________www.scmmetals.com ______________Inside Back Cover Timcal _____________________________+41-91-873-2009 ______www.timcal.com_______________________________31
ADVERTISER’S REQUEST FOR INFORMATION FAX FORM Need more information on products or services seen in this issue?
Complete the form below and fax to the advertiser(s) of your choice. Fax numbers are listed in the advertisers’ index above.
To:___________________________________ Fax #: ______________________________________ Company: _________________________________________________________________________ Please send me more information on:_____________________________________________________ _________________________________________________________________________________ as advertised in the __________ issue of the International Journal of Powder Metallurgy. Please send information to: Name: Title: ________________________________________________________________________ Company: _________________________________________________________________________ Address:___________________________________________________________________________ City:____________________________ State:_______________ Postal Code: ___________________ Country:___________________________________________________________________________ Phone:___________________ Fax:___________________ E-Mail: ___________________________
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A COMMITTED BUSINESS & TECHNICAL PARTNER
Metal Powders
www.qmp-powders.com
