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Powder Metallurgy

FORGING PROCESS OF CONNECTING ROD

Group 1 :Dera LesmanaNetron Silalahi

Chandra SimanjuntakTrie Djoko. S.

Topan NugrahaNatur Paku BirowoNazario Monteiro

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Introduction

Powder metallurgy (P/M) is one of several net or near net shapeprocesses for the manufacture of structural metal parts. Due to lowcost in material and time saving in the consolidation and sinteringprocesses, more and more P/M parts are being used on cars andmotorcycles. But P/M has an obvious disadvantage. It is difficult toachieve alloy steel level on density and mechanical properties.

Although some processes, such as complex pressing, injectionmolding, selecting prealloy powder and warm pressing, can be usedto try to obtain a fully densified part, the density can not reach 96% oftheoretical density. On the other hand, the above processes alsoincrease the cost significantly.

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Elementalor alloymetal

powders

Additive(Die

lubricantsor

graphite)

Mixing

Hot compaction

Isostatic,Extrusion DiecompactingSpraying,Sintering

Pressureless

Cold compaction

Die compacting,Isostatic, Rolling,Injection molding,

Slip casting

Sintering

Vacuum or Atmospheric

Optionalmanufacturing step

Sizing, Repressing,Resintering,

Forging, Coining,Metal infiltration,Oil Impregnation

Optional finishingsteps

Heat treating,Tumbling, Plating,Machining, Stream

treating

Finishproduct

P/M Process

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PRODUCT

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P/M PROCESS

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Composition Design

Several aspects for composition design :

1. Matrix material being carbon steel.

2. Powder porosity being easy to eliminate.

3. Hardenability and the basic hardness more than HRc30 after

hardening.

4. The need of a wear-resisting carburization layer.

5. High powder quality and properties.

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MixingPopular lubricants are stearic

acid, stearin, metallic

stearates, especially zincstearate, and increasingly,

other organic compounds of a

waxy nature.

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Compacting

Synchronous compacting method Density distribution of the rod compact

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Density Compact Formula

= density compactm1 = mass of of the sample in airm2 = mass of the sample in waterm3 = saturant massof the sample taken from water and then cleanedsurface t = density of water measuring temperature t

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Sintering

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Scmetz Vacuum Furnace

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Powder ForgingPowder Forging Die with

Flash No Flash Die of Forging

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Forging Process

Powder forging was performed on a 1600 kN friction screw

process. The pressure was controlled at 1000 1400 Mpa during

forging. The initial forging temperature of the compact was

1100C. In order to protect the compacts from oxidizing, a 4 kVA

furnace was always filled with high purity N 2 gas during heating.

After heating for 10 min, the compact was manually removed from

the furnace and put into the hot forging die quickly. In order to void

oxidation in cooling, the forged compact was dropped into oil

directly after being ejected from the mould.

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Heat Treatment

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Microstructure

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Mechanical Properties

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Conclusions

1. Powder forging of the motorcycle connecting rod is anadvanced process combining the advantages ofpowder metallurgy and precision forging.

2. Fe-C-Cu-Mo alloy powder can exhibit execllentphysical and mechanical properties duringconsolidating, sintering and powder forging.

3. The powder forging process of the connecting rod cansave much material, reduce the equipment capacityand remove the excessive machining.

4. The research results of powder forging the P/Mmotorcycle connecting rod can provide a goodreference to the powder forging of automobileconnecting rods.

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References

1. Guangchun Wang and Guoqun Zhao, PowderForging of a Motorcyle Connecting Rod ,Mold &

Die Engineering Tecnology Research Center,2001.

2. Randal M. German, Powder MetallurgyScience.