Novel sintering strategy for the competitive manufacturing of the high-performance PM components

Purpose and goal

The scope has been realise new combinations of manufacturing steps resulting in significant improvement of existing and new PM alloys. This is expected to facilitate future expansion into high duty applications. The specific goals and activities have been to yield development of improved and new processing chains to reach full density, evaluation of new lean water-atomised steel powder for press&sinter using environmentally friendly alloying elements, establishment of economically feasible sintering routes involving lean atmospheres and vacuum sintering.

Expected results and effects

All goals defined have been reached from a generic proof-of-concept point of view and demonstrator studies have shown how reach pore-free full density starting from agglomerated gas-atomized powder or water-atomized powder. A new lean sintering atmosphere concept for oxidation-sensitive material has been developed and high quality sintering using low-pressure sintering has been demonstrated including promising components testing results. The project has hence provided a platform for further R&D towards implementation of innovative PM solutions.

Planned approach and implementation

This project has involved close co-operation between academia, institute and industry, integrating across the value chain from powder to final product. The work has included theoretical analysis, laboratory experiments, advanced characterisation and final industrial trials with demonstrators. New processing chains to reach full density PM materials as well as lean sintering atmospheres and lean materials have been studied and developed. The work has hence addressed new powder, new sintering solutions and isostatic processing to yield full densification without capsule.