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Article history: This paper presents the effects of forming parameters and sintering schedules to the mechanical proper-
Received 24 May 2011 ties and microstructures of products formed through warm compaction route. A lab scale warm compac-
Accepted 7 July 2011 tion rig is designed and fabricated which enabled the generation of green compacts at different forming
Available online 18 July 2011
parameters. The feedstock was prepared by mechanically mixing the main powder constituent, i.e., iron
ASC 100.29 powder with zinc stearate to reduce the die–wall as well as inter-particle frictions hence
inhomogeneous density distribution could be avoided. The powder mass is formed at different temper-
ature, i.e., 120 °C and 180 °C applying 130 kN axial loading simultaneously from top and bottom punches.
The defect free green compacts were sintered in inert gas fired sintering furnace for different sintering
schedules. The final products were characterized through density measurement, hardness test, and three
point bending test whereas the microstructures were analyzed by Scanning Electron Microscopy (SEM).
The results revealed that the properties of sintered parts formed at 180 °C are better than those formed at
120 °C. The suitable forming parameters and sintering schedules were identified from this study.
Ó 2011 Elsevier Ltd. All rights reserved.
1. Introduction is about 60% of the melting temperature of the main powder con-
stituent, more cumulative atomic motion occurs, leading to im-
A major advance in powder compaction technology is the form- proved inter-particle bonding. However, high temperature, longer
ing of powder mass at above ambient temperature, which can uti- holding time, and small particle size are not always economically
lize traditional powder forming equipment. The powder mass viable for conducting sintering operation. Therefore, control over
together with the die assembly is required to be heated up to a heating rate, time, temperature and atmosphere is required for
temperature below the re-crystallization temperature of the main producible results. In general, the parts tend to densify and im-
powder constituent [1–5]. The process can produce components prove the mechanical properties as sintering proceeds. Increase
having good surface finish and dimensional tolerance hence mini- the density implies an overall shrinkage which leads to complica-
mal further processing is required, therefore less time is taken to tions. The dimensional change is influenced by the green density;
produce an engineering component [6]. the lower this is the greater the tendency to shrink [8].
Density gradients are often evident in green compacts mainly Manufacturing of engineering components through warm form-
due to the complex powder deformation mechanisms occur during ing route involves several key parameters during feedstock prepa-
the compaction phase. These gradients are the main causes of part ration, powder forming, and sintering. Powder forming at above
distortion during the subsequent process of sintering and may ambient temperature is initiated recently and extensive research
even lead to part fracture during its ejection from the die cavity. papers were published [9–17], however less information on the ef-
In order to achieve the required strength in the products, the green fects of warm forming and sintering schedule to the mechanical
compacts formed through warm compaction route are required a properties and microstructures are found. Therefore, this paper
firing treatment known as sintering, which refers to the heat treat- presents the outcome of an extensive research on the effects of
ment of a powder metallurgy green compact for the purpose of forming and sintering parameters to the final performance of the
increasing its strength by bonding together of the particles. Sinter- products formed through warm compaction route.
ing is normally conducted at a temperature where atomic motion
leads to growth of weld bonds among contacting particles [7]. With
2. Experimental procedure
higher temperature or longer holds at the peak temperature, which
A lab scale warm compaction rig was designed and fabricated
⇑ Corresponding author. Tel.: +60 3 89297269; fax: +60 3 89212116. (Fig. 1) which enabled the generation of green compacts at differ-
E-mail address: mujibur@uniten.edu.my (M.M. Rahman). ent forming parameters. Iron ASC 100.29 powder was used during
0261-3069/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2011.07.019
154 M.M. Rahman et al. / Materials and Design 33 (2012) 153–157
0.88
120ºC
0.878 180ºC
0.876
0.872
0.87
0.868
0.866
0.864
0.4 0.8
Lubricant Content (wt%)
the samples were sintered at 900 °C and 1000 °C. The relative den-
the experiment because this type of powder is normally used in sities of the sintered products were measured through dimensional
most of the powder compaction industries [18–20]. The as received measurement and the hardness of the compacts was tested
powder has the particle size range of 20–180 lm. The experiment through Rockwell hardness tester. The strengths of the products
is divided into three sections which are compaction of solid cylin- were measured through three-point bending test (ASTM E290-
drical shape green compacts (Fig. 2), sintering of green compacts in 09) and the microstructures were evaluated through Scanning
argon gas fired sintering furnace, and characterization of final Electron Microscopy (SEM).
products through mechanical testing and microstructure
evaluation.
3. Results and discussions
In order to examine the efficacy of lubricant content, the feed-
stock was prepared by mechanically mixing iron ASC 100.29 pow-
Figs. 3–6 depict the relative density, hardness, bending
der with different weight percent of zinc stearate for 30 min, which
strength, and dimensional changes of the sintered parts formed
is seemed to be adequate [7]. Green sample generation consists of
at different compaction temperature and lubricant content. It is
four consecutive steps which are, die filling with premixed powder
clearly observed that higher relative density can be obtained by
mass, heating of powder mass together with the die assembly,
forming the powder mass at lower temperature both by adding
simultaneous compaction, and ejection of green compacts from
either 0.4 wt% or 0.8 wt% of zinc stearate (Fig. 3). However, addi-
the die cavity by means of bottom punch. The defect-free green
compacts were then sintered in controlled environment, i.e., at a
heating/cooling rate of 10 °C/min, a holding time of 30 min. All 107
120ºC
180ºC
106
Rockwell Hardness (HRF)
105
104
103
0.4 0.8
Lubricant Content (wt%)
700 0.88
120ºC 30ºC
150ºC
600 180ºC
180ºC
0.86 180ºC 0.4wt%
500
Relative Density ( ρr )
Strength (MPa)
0.84
400
300
0.82
200
0.80
100
0 0.78
0.4 0.8 900 1000
Lubricant Content (wt%) Sintering Temperature (ºC)
Fig. 5. Strength of sintered parts. Fig. 7. Relative densities of sintered parts at different sintering temperature.
1.40 110
30ºC
120ºC 150ºC
180ºC
1.20 180ºC 180ºC 0.4wt%
108
Rockwell Hardness (HRF)
Dimensional Changes (%)
1.00
106
0.80
0.60 104
0.40
102
0.20
100
900 1000
0.00
0.4 0.8 Sintering Temperature (ºC)
Lubricant Content (wt%)
Fig. 8. Hardness of sintered parts at different sintering temperature.
Fig. 6. Dimensional change of sintered parts.
700
30ºC
600 150ºC
180ºC
180ºC 0.4wt%
500
Strength (MPa)
400
300
200
100
0 Fig. 11. Micrograph of sintered product; 0.4 wt% lubricant, formed at 180 °C.
900 1000
Sintering Temperature (ºC)
Fig. 12. Micrograph of sintered product; 0.8 wt% lubricant, formed at 120 °C.
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