Manganese as Manganese as a primary a primary alloying alloying element element Dennis Hammond –Apex Dennis Hammond –Apex Advanced TechnologiesAdvanced Technologies

Richard R. Phillips – Engineered Richard R. Phillips – Engineered Pressed MaterialsPressed Materials

Manganese BackgroundManganese Background Manganese metal admixed subject to Manganese metal admixed subject to

HydrolysisHydrolysis , oxidation in P/M application, oxidation in P/M application Manganese as a pre-alloy, hard to Manganese as a pre-alloy, hard to

compress, limited use levelscompress, limited use levels Ferro Manganese abrasive, patentsFerro Manganese abrasive, patents Highest performance alloying element- Highest performance alloying element-

strength, hardenabilitystrength, hardenability Previous work demonstrated feasibility of Previous work demonstrated feasibility of

using Manganese metal admixed both as a using Manganese metal admixed both as a sinter hardened and case hardened lean sinter hardened and case hardened lean formulationsformulations

Manganese Background Manganese Background Cont.Cont.

Manganese as an admix demonstrated Manganese as an admix demonstrated feasibility in multiple production furnaces in feasibility in multiple production furnaces in previous workprevious work

Manganese coated for protection from Manganese coated for protection from hydrolysis and oxidation during blending, hydrolysis and oxidation during blending, storage and handling, supplied as master storage and handling, supplied as master batch batch

Press conditions developed for maximizing Press conditions developed for maximizing protection during de-lubing and sinteringprotection during de-lubing and sintering

Key FeaturesKey FeaturesAdditive/Lubricant Master BatchAdditive/Lubricant Master Batch

Calculations for feasibility of density, Calculations for feasibility of density, desired lubrication, and needed additivesdesired lubrication, and needed additives

Target volume 98.5-99.5% of theoretical at Target volume 98.5-99.5% of theoretical at target green densitytarget green density

Need for a green compact free of density Need for a green compact free of density gradients, semi-hydrostatic gradients, semi-hydrostatic

Need for excellent lubrication, Apex Need for excellent lubrication, Apex SuperlubeSuperlube®®

Need for mobile lubricant to achieve best fit Need for mobile lubricant to achieve best fit of metal particles during compaction and of metal particles during compaction and spread of additivesspread of additives

Key FeaturesKey FeaturesAdditive/Lubricant Master BatchAdditive/Lubricant Master Batch

Need for excellent distribution and Need for excellent distribution and dispersion of additives in a segregation dispersion of additives in a segregation free powder mix and compactfree powder mix and compact

Protection of reactive additives by coating Protection of reactive additives by coating particlesparticles

Master batch includes all additives Master batch includes all additives including proprietary additives, pre-mixed including proprietary additives, pre-mixed and screened, ready to mix with iron and screened, ready to mix with iron powder for easy mixingpowder for easy mixing

Test Matrix for Test Matrix for evaluationevaluation Fixed Density -7.25g/cc greenFixed Density -7.25g/cc green

Fixed Carbon- 0.3%Fixed Carbon- 0.3% Compressible iron- AT1001HPCompressible iron- AT1001HP Mn content- 0%, 0.5%, 0.75%, 1%,1.5%, Mn content- 0%, 0.5%, 0.75%, 1%,1.5%,

2%2% Sintering- in various production Sintering- in various production

furnaces, conventional gas 2050furnaces, conventional gas 2050F, rapid F, rapid cool 2050cool 2050F and 2265F and 2265F, rapid cool F, rapid cool vacuum 2265vacuum 2265F and 2350F and 2350FF

Test Matrix for Test Matrix for evaluationevaluation

Heat treatment- .6%carbon potential, Heat treatment- .6%carbon potential, temper at 350Ftemper at 350F

Test- carbon content, size change, Test- carbon content, size change, sintered density, TRS strength, sintered density, TRS strength, hardness, and Impact hardness, and Impact

Carbon content after Carbon content after Sintering 2050 F slow Sintering 2050 F slow

coolcool% Mn % C before sinter % C after Sinter

0 0.3% 0.26%

0.5% 0.3% 0.29%

0.75% 0.3% 0.29%

1% 0.3% 0.29%

1.5% 0.3% 0.29%

2% 0.3% 0.30%

Conclusions- Carbon lossConclusions- Carbon loss

Less losses of Graphite with Manganese Less losses of Graphite with Manganese than with plain ironthan with plain iron

Manganese well protected using this Manganese well protected using this coating technologycoating technology

6.95

7

7.05

7.1

7.15

7.2

7.25

7.3

De

ns

ity

(g

/cm

3)

0% Mn 0.5% Mn 0.75%Mn

1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn Steel Density vs Mn Content

for Various Sintering Processes in the as Sintered Condition

2050F 1121C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum

7

7.05

7.1

7.15

7.2

7.25

7.3

Den

sity

(g

/cm

3 )

0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn Steel Density vs. Mn Content

for Various Sintering Processes with Heat Treating and Temper at 350F

2050F 1121C slow cool gas HT 2265F 1240C fast cool vacuum HT2265F 1240C fast cool gas HT 2350F 1288C fast cool vacuum HT

-0.40%

-0.30%

-0.20%

-0.10%

0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

0.60%

0.70%

0.80%

% S

ize c

ha

ng

e

0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn Steel Size Change from Die Size vs Mn Content

of Various Sintering Processes in the as Sintered Condition

as molded 2050F 1121C slow cool gas2265F 1240C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum

-0.40%

-0.30%

-0.20%

-0.10%

0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

0.60%

0.70%

0.80%

Siz

e C

han

ge

0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn SteelSize Change from Die Size vs. Mn Content

of Various Sintering Processes with Heat Treating and Temper at 350F

As molded 2050F 1121C slow cooled gas HT

2050F 1121C fast cooled gas HT 2265F 1240C fast cooled gas HT

2265F 1240C fast cooled vacuum HT 2350F 1288C fast cooled vacuum HT

Conclusions- density and Conclusions- density and sizesize

Higher sintering temperature results in Higher sintering temperature results in higher sintered densityhigher sintered density

Increased Mn leads to increased growth Increased Mn leads to increased growth Sintering1% Mn at 2265F/1240C appears Sintering1% Mn at 2265F/1240C appears

optimum for densityoptimum for density 0.75 to1% Mn gives near neutral growth 0.75 to1% Mn gives near neutral growth

<0.1% change considered to be ideal <0.1% change considered to be ideal

0

20

40

60

80

100

120

140

160

180

TRS

Str

engt

h

0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn Steel TRS Strength vs. Mn Content

for Various Sintereing Processes as Sintered Condition

2050F 1121C fast cooled gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum

0

20

40

60

80

100

120

140

160

180

TR

S S

tren

gth

0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn SteelTRS Strength vs. Mn Content

for Various Sintereing Process in the Heat Treating and Temper at 350F

2050F 1121C slow cool gas 2265F 1240C fast cool vacuum2265F 1240C fast cool gas 2350F 1288C fast cool vacuum

Conclusions –TRS Conclusions –TRS StrengthStrength

0.75% Mn appears to be optimum for 0.75% Mn appears to be optimum for TRSTRS

Near 100% improvement in strength at Near 100% improvement in strength at higher temperatures over 2050F/1121Chigher temperatures over 2050F/1121C

Heat treated 0.5% Mn gives optimum Heat treated 0.5% Mn gives optimum results results

30

40

50

60

70

80

90

Har

dn

ess

HR

B

0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn SteelHardness vs. Mn Content

for Various Sintering Processes as Sintered Condition

2050F 1121C slow cool gas 2050F 1121C fast cool gas2265F 1240C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum

30

32

34

36

38

40

42

44

46

48

50

Ha

rdn

es

s H

RC

0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn SteelHardness vs. Mn Content

of Various Sintering Processes with Heat Treating and 350F Temper

2050F 1121C slow cool gas HT 2265F 1240C fast cool gas HT2265F 1240C fast cool vacuum HT 2350F 1288C fast cool vacuum HT

Conclusions- hardnessConclusions- hardness

As sintered general improvement in As sintered general improvement in hardness with increased Mn contenthardness with increased Mn content

Hardness after heat treatment no Hardness after heat treatment no significant improvement after 0.75% Mnsignificant improvement after 0.75% Mn

Hardness after heat treatment with Hardness after heat treatment with 0.75% Mn all 44 HRC and above 0.75% Mn all 44 HRC and above

0

5

10

15

20

25

30

35

40

45

Imp

act

ft-l

bs.

0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn SteelImpact vs. Mn content

of Various Sintering Processes as Sintered Condition

2050F 1121C slow cool gas 2050F 1121C fast cool gas2265F 1240C fast cool gas 2265F 1240C fast cool vacuum2350F 1288C fast cool vacuum

0

2

4

6

8

10

Imp

act

ft-l

bs.

0.0% Mn 0.5% Mn 0.75% Mn 1.0% Mn 1.5% Mn 2.0% Mn

MPIF 2011 Mn SteelImpact vs. Mn Content

of Various Sintering Processes with Heat Treating and a Temper of 350T

2050F 1121C slow cool gas HT 2050F 1121C fast cool gas HT2265F 1240C fast cool gas HT 2265F 1240C fast cool vacuum HT2350F 1288C fast cool Vacuum HT

Conclusions -ImpactConclusions -Impact

0.5% -0.75% Mn optimum for impact0.5% -0.75% Mn optimum for impact Fast cooling gas furnace gave the best Fast cooling gas furnace gave the best

impact impact Mn coupled with higher temperature Mn coupled with higher temperature

sintering can give dramatic sintering can give dramatic improvements of impact strength improvements of impact strength

Over all conclusionsOver all conclusions Elemental Mn can be protected and Elemental Mn can be protected and

effectively used in powdered metaleffectively used in powdered metal No significant carbon lossNo significant carbon loss No compromise of compressibilityNo compromise of compressibility Properties can generally be improved Properties can generally be improved

with Mn levels of 0.5 to 1%with Mn levels of 0.5 to 1% Increased sintering temperature gives Increased sintering temperature gives

improved properties with Mn containing improved properties with Mn containing formulasformulas

Over all conclusions, Over all conclusions, Cont.Cont.

Mn can be a cost effective alloying Mn can be a cost effective alloying element element

Mn can be used in powdered metal on Mn can be used in powdered metal on convention sintering furnacesconvention sintering furnaces

Mn can be substituted for other more Mn can be substituted for other more costly alloying elements costly alloying elements

AcknowledgmentsAcknowledgments

Horizon, Ridgway Powder Metals, Horizon, Ridgway Powder Metals,

Engineered Pressed Materials, Engineered Pressed Materials, Advantage Metal Powders,Advantage Metal Powders,

Product AssuranceProduct Assurance