U.S. patent number 3,785,038 [Application Number 05/217,510] was granted by the patent office on 1974-01-15 for process of working a sintered powder metal compact.
This patent grant is currently assigned to Sintermetallwerk Krebsoge GmbH. Invention is credited to Gerhard Zapf.
United States Patent |
3,785,038 |
Zapf |
January 15, 1974 |
PROCESS OF WORKING A SINTERED POWDER METAL COMPACT
Abstract
A process of manufacturing articles by means of powder
metallurgy, including the conventional steps of forming a blank out
of metal powder compressing the blank and sintering it. Pursuant to
the disclosure, an additional step is provided, wherein the
sintered blank is subjected in a die to one or more further press
operations in which the material of the blank is allowed to flow
freely in the direction transverse to the direction in which
pressure is applied. In this manner the density of the product is
increased. Preferably the article is sintered again or annealed
after the further press operation or operations to provide it with
the required strength characteristics. The additional step is
advantageously carried out at room temperature.
Inventors: |
Zapf; Gerhard (Krebsoge/Rhld.,
DT) |
Assignee: |
Sintermetallwerk Krebsoge GmbH
(Krebsoge/Rhld., DT)
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Family
ID: |
5695254 |
Appl.
No.: |
05/217,510 |
Filed: |
January 13, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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849354 |
Aug 12, 1969 |
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Foreign Application Priority Data
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Aug 20, 1968 [DT] |
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1758849 |
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Current U.S.
Class: |
419/28; 419/29;
29/DIG.47 |
Current CPC
Class: |
B22F
3/16 (20130101); Y10S 29/047 (20130101) |
Current International
Class: |
B22F
3/12 (20060101); B22F 3/16 (20060101); B22f
003/24 () |
Field of
Search: |
;29/420,420.5,DIG.31,DIG.47 ;264/111 ;75/200 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Herbst; Richard J.
Assistant Examiner: Reiley, III; D. C.
Attorney, Agent or Firm: David Toren et al.
Parent Case Text
CROSS-REFERENCE TO PRIOR APPLICATION
This is a continuation-in-part of copending application Ser. No.
849,354, filed Aug. 12, 1969, and now abandoned.
FIELD OF INVENTION
The invention relates to the manufacture of articles by powder
metallurgy, wherein a blank is formed from metal powder, whereafter
the blank is compressed and sintered.
BACKGROUND INFORMATION
Articles can be made using metal powders as a raw material by what
is called the powder metallurgical process. This process is used in
particular where other manufacturing processes such as casting,
forging or machine cutting cannot be used, or only at high cost and
under technical difficulties. The principle involved in the powder
metallurgical process of manufacture is that a metal powder, or a
mixture of powders consisting of metals and non-metals, is formed
into the shape of the product by compression in a die. The blank
formed in this way is then sintered at a high temperature.
A precise quantity of the metal powder, measured either by volume
or by weight, is introduced into the die and compressed by a punch.
Alternatively, in order to obtain a more homogeneous densification,
two punches can be used acting in opposite directions. The
densified intermediate product obtained in this way is a compressed
blank whose shape and dimensions are determined by the shapes of
the press tools used, and by the amount of pressure applied. The
compressed blank is then sintered at a high temperature so as to
bond the particles together by a process of diffusion. To prevent
oxidation of the material, the sintering is usually conducted under
a protective gas, or in a reducing atmosphere.
In order to improve the dimensional accuracy of the finished
product it is known to subject the product, after sintering, to a
second press operation called calibrating or sizing. The sizing is
done by subjecting the product to a second press operation in a
completely closed die, to the effect that at the end of the sizing
operation the product is a precise positive replica of the fully
closed die, which can be regarded as the corresponding negative
shape, or female mould.
It is known that the mechanical strength of a sintered product is a
function of its density. Both the tensile strength and the hardness
increase linearly with density. On the other hand, the dynamic
properties of the product for example the elongation at rupture,
the notch impact strength and the elasticity increase non-linearly
with the density. What this means in practice is that sintered
products which are going to be subjected to high working stresses,
for example in the processing industries, must have a high
density.
However, it has been found that economically obtainable pressures
can give no more than approximately 85 percent at most of the
theoretical maximum density, that is to say of the density which
one would obtain in a completely compacted product. The compaction
is limited mainly by the fact that the material work hardens during
the press operation, preventing complete compaction.
It is possible, by particularly difficult and costly process, to
give a product made of a soft metal a density as high as 93 to 96
percent of the theoretical value. This is obtained by subjecting
the compressed blank to an annealing or pre-sintering operation and
then pressing it again. This method is called double pressing, but
is still not capable of compacting the material completely.
It is nowadays becoming increasingly important to produce sintered
products of high density, because sintered products are being used
increasingly as stressed parts in various applications,
particularly in civil engineering.
SUMMARY OF INVENTION
The object of the present invention is to provide a simple process
for producing products by powder metallurgy which have densities
considerably higher than those hitherto obtainable.
To this end, according to this invention, an article is
manufactured by powder metallurgy by a process in which, after a
blank has been compressed and sintered, it is then subjected to one
or more further press operations in a die in which the material of
the blank is allowed to flow freely in the direction transverse to
the direction in which pressure is applied. This further press
operation is advantageously performed at room temperature.
Articles made in this way have a very high density and great
mechanical strength. The new process is based on the surprising
discovery that sintered products, even though consisting of porous
material, are nevertheless capable of undergoing considerable
plastic deformation, involving a free flow of the material. This
can be shown, for example, quite simply by squashing a sample
between two flat plates. Using comparatively little pressure,
densities are obtained as high as 99.0 to 99.6 percent of the
theoretical maximum value.
The process, in accordance with the invention for producing
sintered articles is quite simple. In the first stage of the
process a measured quantity of a metal powder is compressed in a
press to produce a compressed blank having a density between 50 and
85 percent of the theoretical density. In this first compression
the press tools can be of customary construction. In the second
stage of the process, the pressed blank is sintered in the usual
way, preferably under a protective gas. In the third stage of the
process the compressed and sintered blank is subjected to a second
press operation using press tools arranged in such a way that the
material can flow freely in the direction transverse to the
direction in which pressure is applied, without being impeded by
the press tools. This, of course, requires that there is sufficient
space between the wall of the die and the blank. Thus, the lateral
dimension, to wit, the dimension of the die which is transverse to
the pressure direction, must be larger than the lateral dimension
of the blank to be compressed so that the walls of the die do not
form any resistance to the free flow of the material during the
press operation. By this method, the density of the product is
increased to between 85 and 99.9 percent of the theoretical maximum
density. The re-densification of the product, or
super-densification, can, if desired, be repeated several times.
The product is at the same time given a different shape by the
re-densification press operation.
Products which have been re-densified in this way can often be used
without further processing, provided that only tensile strengths
are involved, that is to say, not elongation at rupture. However,
the product is preferably subjected to a fourth stage of the
process, in which it is either sintered or annealed, This gives the
optimum tensile strength and elongation at rupture. Finally, the
product can be calibrated, hot or cold, stamped or embossed, or
forged.
It has been found that sintered products made by the process of the
present invention are so tough that they can be used as initial
blanks for cold forging, extrusion pressing or flow pressing to
give final products of complex shape by deformation without
cutting. Furthermore, due to their comparatively high densities,
these sintered products can be used as initial blanks for precision
forging. This amounts in practice to hardly more than a final
calibration of the product at high temperature, and requires only
comparatively moderate pressures. Sintered products made in
accordance with the present invention have also been found suitable
for use as initial blanks for cold embossing.
Claims
What I claim is:
1. In a process for manufacturing an article by powder metallurgy
comprising the steps of forming a blank from metal powder,
compressing said blank and sintering said blank, the improvement
comprising the additional step of subjecting said compressed and
sintered blank to a least one additional press operation in a die
in which the material of said blank is allowed to flow freely in
the direction transverse to the direction in which pressure is
applied and carrying out the at least one additional press
operation at room temperature.
2. A process as claimed in claim 1, wherein said blank is deformed
during said additional press operation to form said article to its
final shape.
3. A process as claimed in claim 1, comprising the further step of
sintering or annealing said blank after said further press
operation.
4. A process as claimed in claim 1, wherein a plurality of said
additional press operations are performed.
5. A process as claimed in claim 1, wherein the additional press
operation is carried out so as to increase the diameter of the
blank.
Description
An example of a process in accordance with the invention will now
be described with reference to the accompanying drawings in
which:
FIG. 1 is a side elevational view of a cylindrical, compressed
sintered blank;
FIG. 2 shows the blank of FIG. 1 after it has been shaped into an
article by being subjected to an additional press operation in
accordance with the invention;
FIG. 3 shows the article of FIG. 2 which, after a heat treatment,
has again been subjected to a press operation pursuant to the
invention;
FIG. 4 shows the finished article which has been obtained by
subjecting the article of FIG. 3 to a further inventive press
operation; and
FIG. 5 is a vertical section through a press arrangement suitable
for carrying out the inventive procedure.
The cylindrical blank 1 of FIG. 1 has a diameter of 15.1 mm and a
height of 14.8 mm, as well as a hardness HB 5/2.5 of 63
kp/mm.sup.2. The blank was formed in customary manner from
electrolytic iron powder which was cold-pressed and subsequently
sintered for about 1 hour at 1250.degree.C in a cracked-gas
atmosphere. The sintered blank thus obtained was then shaped in
accordance with the invention by subjecting it to an additional
press operation. This was effected in the press arrangement of FIG.
5 having a die 4 which is sufficiently large so as to allow the
material of the blank of FIG. 1 to flow freely within the die in
the direction transverse to the direction in which pressure is
applied. The additional press operation in the press of FIG. 5 was
carried out at oom temperature and at a pressure of 2 Mp/cm.sup.2.
During this additonal pressing, the material of the blank flowed
within the die in outward direction, to wit toward the die wall,
transverse to the direction of pressure, namely transverse to the
direction of movement of the punch tool. In this manner, the
article shape 1a shown in FIG. 2 was obtained. This shape 1a, which
thus corresponds substantially to a round disc, had a diameter of
24 mm and a hiehgt of 6.4 mm. This means that the diameter, as
compared to the diameter of the original blank 1 of FIG. 1
increased by almost 9 mm. While the density of the blank 1 of FIG.
1 was 7.3-7.4 g/cm.sup.3, the density of the article 1a of FIG. 2
rose to 7.8 g/cm.sup.3. The Brinell hardness value was 140
kp/mm.sup.2.
Subsequent to the formation of the article of FIG. 2, the disc 1a
thus obtained was heated for 1 hour at 1250.degree.C in a gas
atmosphere in order to restore the formability of the cracked
article which is largely lost by the cold-shaping in the press. The
heat-treated article of FIG. 2 was then cooled to room temperature
and had a density of 7.75 g/cm.sup.3 and a Brinell hardness of 71
kp/mm.sup.2. The article was then again inserted into the press of
FIG. 5 and shaped while permitting the material of the article to
flow freely in the direction transverse to the press direction. In
this manner and without changing the density, the Brinell hardness
value increased to 146 kp/mm.sup.2 while the article assumed the
dish-like shape 1b of FIG. 3. During this second press operation as
described above, the diameter of the article did not change.
However, this fact notwithstanding and due to the deformation of
the article into a dish-like shape, the material of the article did
flow freely in the direction transverse to the press direction, to
wit, a radial return flow in the direction towards the press axis
took place.
The article 1b obtained according to FIG. 3 was finally subjected
to a terminal cold-shaping in which the material of the article
flowed freely in lateral direction, whereby the article of the
final shape 1c, shown in FIG. 4, was obtained. The largest diameter
of this article 1c was 27.8 mm while its height was 13 mm. It
follows that the diameter increase from the original blank of FIG.
1 to the final article 1c of FIG. 4 was more than 12 mm. The
density of the article changed during the final cold shaping by an
insignificant degree only and thus has a value of 7.8 g/cm.sup.3.
By contrast, the Brinell hardness increased significantly and
indicated a final value of 165 kp/mm.sup.2.
The data of the above experiment are compared in the following
Table with the results of additional tests which were carried out
with a powder RZ 150 prepared according to the so-called RZ-process
developed by G. Naeser, H. Steffe and W. Scholz. ##SPC1##
The data of the Table indicate that the inventive procedure results
in a significant increase in the density. Such density increase
cannot be obtained according to the prior art procedure, for
example according to the customary double-press technique. This
could be demonstrated by a comparison test wherein an electrolytic
iron powder corresponding to the powder of the above test could be
compacted to a density of 7.4 g/cm.sup.3 only. Further, the data of
the Table indicate that the increase in the density causes also a
significant increase in the hardness and thus also in the strength
of the article. The increase in the strength values is demonstrated
by the fact that the starting blank of FIG. 1 has a tensile
strength of 25 kp/mm.sup.2 while the final article of FIG. 4 has a
tensile strength of 54 kp/mm.sup.2.
The pressing is preferable performed by press tools, as shown in
FIG. 5, consisting of an upper punch 2, with an exchangeable punch
tool 3, working in a die 4. The redensified product 1a of FIG. 2 is
introduced into the die 4 through an opening 5. The die 4 rests on
a pressure plate 6, which rests on a spacer ring 7 reposing on a
base plate 8. The spacer ring 7 contains a foot plate 9 of an
ejector piston 10 which works in bores passing through the pressure
plate 6 and the die 4. An ejector pin 11 works in a bore in the
base plate 8 and acts on the foot 9 of the ejector piston 10, so
that when the pin 11 is lifted, the piston 10 pushes the deformed
product 1b out of the die 4 through the upper opening 5. The
additional press operations may be performed in the same press
arrangement by choosing suitable punch tools and die. The die, of
course, has always to be sufficiently large so as to permit the
free flow in transverse direction.
* * * * *