Abstract
A novel approach to reach full density in powder metallurgy (PM) components is demonstrated in this work. Water-atomised Mo-prealloyed steel powder is utilised for manufacturing cylindrical and gear samples through double pressing and double sintering (DPDS) process route. The effect of sample geometry and powder size fraction on densification is investigated and it is found that the DPDS route enables a density level of > 95% which is sufficient to eliminate the surface open pores. Reaching such high density is necessary, in order to perform capsule-free hot isostatic pressing (HIP). After HIP, full densification is achieved for the cylindrical samples and only near full density is realised for the gears resulting in neutral zone formation due to the density gradient. In order to predict the densification behaviour during the compaction, FEM simulations considering the gear geometry are performed for both the pressing stages and HIP. The simulation predicted a similar densification behaviour with the formation of the neutral zone. The proposed DPDS route with capsule-free HIP in combination with FEM simulation is demonstrated as a potential route for manufacturing full-density PM steel components, e.g. gears, suitable for high-performance applications.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Krokha VA, Bakhovkin AM (1964) An advanced method for the manufacture of gears. Sov Powder Metall Met Ceram 2:81–85. https://doi.org/10.1007/BF00774142
Mascarenhas J (2004) Powder metallurgy: a major partner of the sustainable development. Mater Sci Forum 455:857–860
Dale JR (2011) Powder metallurgy-intrinsically sustainable. Int J Powder Metall (Princeton, New Jersey) 47:27–31
Hadrboletz A, Weiss B (1997) Fatigue behaviour of iron based sintered material: a review. Int Mater Rev 42:1–44. https://doi.org/10.1179/imr.1997.42.1.1
Danninger H, Spoljaric D, Weiss B, Stickler R (1998) High cycle fatigue behaviour of Mo alloyed sintered steel. Z Met Res Adv Tech 89:135–141
Zhang L, Liu Z, Sun H, Qin M, Qu X, Lyu Y (2017) Dynamic properties of high-density low-alloy PM steels. Powder Metall 60:56–65. https://doi.org/10.1080/00325899.2016.1274815
Beiss P (2003) Iron and steel: manufacturing route, chap 5, structural mass production. Landolt-börnstein—gr. VIII Adv. Mater Technol:5–20
Beiss P, Dalgic M (2001) Structure property relationships in porous sintered steels. Mater Chem Phys 67:37–42. https://doi.org/10.1016/S0254-0584(00)00417-X
Andersson M, Larsson M (2010) Linking pore size and structure to the fatigue performance of sintered steels. PM2010 World Congr. – Fatigue Sintered Steels
Andersson M (2011) The role of porosity in fatigue of PM materials. Powder Metall Prog 11:21–31
Cipolloni G, Menapace C, Cristofolini I, Molinari A (2014) A quantitative characterisation of porosity in a Cr–Mo sintered steel using image analysis. Mater Charact 94:58–68. https://doi.org/10.1016/j.matchar.2014.05.005
Engström U, Fordén L, Bengtsson S, Bergström M (2006) Surface densification and warm compaction lead to greater density in PM gears, resulting in higher strength and improved fatigue properties. Gear Solut 18–22
Dizdar S (2012) High-performance sintered-steel gears for transmissions and machinery : a critical review. Gear Technol 60–65
Flodin A, Andersson M, Miedzinski A (2016) Full density powder metal components through hot isostatic pressing. Met Powder Rep 72:2–5. https://doi.org/10.1016/j.mprp.2016.02.057
Strondl A, Khodaee A, Vattur Sundaram M, et al (2016) Innovative powder based manufacturing of high performance gears. World PM 2016 Congr. Exhib
Vattur Sundaram M (2017) Processing methods for reaching full density powder metallurgical materials. Chalmers University of Technology
Essa K, Jamshidi P, Zou J, Attallah MM, Hassanin H (2017) Porosity control in 316L stainless steel using cold and hot isostatic pressing. Mater Des 138:21–29. https://doi.org/10.1016/j.matdes.2017.10.025
Hassanin H, Al-Kinani AA, ElShaer A et al (2017) Stainless steel with tailored porosity using canister-free hot isostatic pressing for improved osseointegration implants. J Mater Chem B 5:9384–9394. https://doi.org/10.1039/C7TB02444D
Magnusson H, Frisk K, Vattur Sundaram M, et al (2016) Reaching full density of 100Cr6 PM steel by capsule free hot isostatic pressing of high-velocity compacted material. World PM 2016 Congr. Exhib
Eklund A, Ahlfors M (2018) Heat treatment of PM parts by hot isostatic pressing. Met Powder Rep 73:163–169. https://doi.org/10.1016/j.mprp.2018.01.001
Dlapka M, Danninger H, Gierl C, Lindqvist B (2010) Defining the pores in PM components. Met Powder Rep 65:30–33. https://doi.org/10.1016/S0026-0657(10)70093-X
Ahlfors M (2014) The possibilities and advantages with heat treatments in HIP. HIP14 Proc.
Materials and powder properties 1. In: Höganäs Handb. Sintered Components. https://www.hoganas.com/globalassets/uploaded-files/handbooks/handbook-1-material_and_powder_properties_december_2013_0674hog-interactive.pdf. Accessed 30 Jul 2018
Semel FJ, Lados DA (2006) Porosity analysis of PM materials by helium pycnometry. Powder Metall 49:173–182. https://doi.org/10.1179/174329006X95347
Hrairi M, Chtourou H, Gakwaya A, Guillot M (2011) Modeling the powder compaction process using the finite element method and inverse optimization. Int J Adv Manuf Technol 56:631–647. https://doi.org/10.1007/s00170-011-3211-z
Drucker DC, Prager W (1952) Soil mechanics and plastic analysis or limit design. Q Appl Math 10:157–165
Gurson AL (1977) Continuum theory of ductile rupture by void nucleation and growth: part I—yield criteria and flow rules for porous ductile media. J Eng Mater Technol 99:2–15. https://doi.org/10.1115/1.3443401
Wagle GS (2006) Die compaction simulation: simplifying the application of a complex constitutive model using numerical and physical experiments
Khodaee A, Melander A (2017) Evaluation of effects of geometrical parameters on density distribution in compaction of PM gears. AIP Conf Proc. https://doi.org/10.1063/1.5008051
Slimane A, Bouchouicha B, Benguediab M, Slimane S-A (2015) Parametric study of the ductile damage by the Gurson–Tvergaard–Needleman model of structures in carbon steel A48-AP. J Mater Res Technol 4:217–223. https://doi.org/10.1016/j.jmrt.2014.12.011
Bourih A, Kaddouri W, Kanit T, Madani S, Imad A (2018) Effective yield surface of porous media with random overlapping identical spherical voids. J Mater Res Technol 7:103–117https://doi.org/10.1016/j.jmrt.2017.01.002
Rutz HG, Hanejko FG (1994) High density processing of high performance ferrous materials. Adv Powder Metall Part Mater 5:117
Hanejko F (2010) High density via single pressing/single sintering. Fenmo Yejin Jishu/Powder Metall Technol 28:73–76
Acknowledgements
The authors would like to acknowledge Vinnova (Swedish agency for innovation systems) for funding the HIP Gear project (Dnr: 2013-05594) within the framework of the FFI programme. Magnus Ahlfors from Quintus Technologies AB is acknowledged for supporting with the HIP trails.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Vattur Sundaram, M., Khodaee, A., Andersson, M. et al. Experimental and finite element simulation study of capsule-free hot isostatic pressing of sintered gears. Int J Adv Manuf Technol 99, 1725–1733 (2018). https://doi.org/10.1007/s00170-018-2623-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2623-4