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Патент США № | 7416578 |
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Автор(ы) | Ahlin и др. |
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Дата выдачи | 26 августа 2008 г. |
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Powder metal composition
РЕФЕРАТ
The invention concerns a powder metal composition comprising an iron based powder and a lubricant and/or binder comprising at least one secondary amide of the general formula: R.sub.1--NH--CO--R.sub.2, wherein R.sub.1 and R.sub.2 are the same or different, straight or branched, saturated or unsaturated aliphatic hydrocarbon groups. The invention further concerns a method of making green bodies of the powder metal composition according to the invention, a method of producing a bonded iron-based powder composition, as well as the use of the at least one secondary amide as a lubricating and/or binding agent for iron based powders and the use as a die wall lubricant.
Авторы: | .ANG.sa Ahlin (Hoganas, SE), Maria Ramstedt (Helsingborg, SE)
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Заявитель: | Hoganas AB (Hoganas, SE)
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ID семейства патентов | 36566182 |
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Номер заявки: | 11/228,257 |
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Дата регистрации: | 19 сентября 2005 г. |
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Prior Publication Data
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| Document Identifier | Publication Date |
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| US 20060112783 A1 | Jun 1, 2006 |
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Отсылочные патентные документы США
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| Application Number | Filing Date | Patent Number | Issue Date | |
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| 60621805 | Oct 26, 2004 | | | |
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Приоритет зарубежной заявки
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| Sep 17, 2004 [SE] | | | 0402239 |
| Jan 12, 2005 [SE] | | | 0500072 |
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Класс патентной классификации США: | 75/252; 419/35; 419/36; 419/37 |
Класс совместной патентной классификации: | B22F 1/0059 (20130101); C10M 105/68 (20130101); C10M 2201/041 (20130101); C10M 2201/0413 (20130101); C10M 2201/061 (20130101); C10M 2201/066 (20130101); C10N 2240/58 (20130101); C10M 2215/0806 (20130101); C10N 2220/08 (20130101); C10N 2230/06 (20130101); C10M 2215/0806 (20130101); C10M 2215/0806 (20130101) |
Класс международной патентной классификации (МПК): | B22F 1/00 (20060101); B22F 1/02 (20060101); B22F 3/00 (20060101) |
Область поиска: | ;75/252 ;419/35,36,37 |
Использованные источники
[Referenced By]
Патентные документы США
Зарубежные патентные документы
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| 0 589 088 | | Mar 1994 | | EP |
| 1197975 | | Apr 2002 | | EP |
| 1205949 | | May 2002 | | EP |
| 1276119 | | Jun 2007 | | EP |
| WO94/02273 | | Feb 1994 | | WO |
| WO01/22448 | | Mar 2001 | | WO |
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Главный эксперт: King; Roy
Assistant Examiner: Mai; Ngoclan T
Уполномоченный, доверенный или фирма: Buchanan Ingersoll & Rooney PC
ФОРМУЛА ИЗОБРЕТЕНИЯ
The invention claimed is:
1. Powder metal composition for compaction when producing powder metal components comprising an iron based powder selected from pure iron, iron powder pre-alloyed, diffusion annealed or mixed with alloying, element(s) selected from Cu, Mo, Cr, Mn, P, C, Ni, Si, B, V, Ti, Al, Co, W, or mixtures thereof and a lubricant and/or binder comprising 0.05-2% by weight of at least one secondary amide of the general formula: R.sub.1--NH--CO--R.sub.2 wherein R.sub.1 and R.sub.2 are the same or different, straight or branched, saturated or unsaturated aliphatic hydrocarbon groups.
2. Composition according to claim 1, wherein R.sub.1 and R.sub.2 independently include 10 to 24 carbon atoms.
3. Composition according to claim 1 wherein R.sub.1 and R.sub.2 are selected from the group consisting of alkyl and alkenyl.
4. Composition according to claim 3, wherein the alkyl groups are chosen from decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl, docosyl, tricosyl and tetracosyl.
5. Composition according to claim 3, wherein the alkenyl groups are chosen from decenyl, undecenyl, dodecenyl, tridecenyl, tetradecenyl, pentadecenyl, hexadecenyl, heptadecenyl, octadecenyl, nonadecenyl, elcosenyl, heneicosenyl, docosenyl, tricosenyl, and tetracosenyl.
6. Composition according to claim 1, wherein the secondary amide is chosen from oleyl palmitamide, stearyl stearamide, oleyl stearamide, stearyl oleamide, oleyl oleamide, stearyl erucamide, oleyl erucamide, erucyl stearamide, erucyl oleamide, erucyl erucamide, lignoceryl lauramide, and lignoceryl stearamide.
7. Composition according to claim 1, further comprising at least one primary amide.
8. Composition according to claim 7, wherein the primary amide is an amide of a saturated or unsaturated, straight fatty acid having 12-24 carbon atoms.
9. Composition according to claim 7, wherein the primary amide is selected from the group consisting of palmitamide, stearamide, arachidamide, behenamide and erucamide.
10. Composition according to claim 1, wherein the lubricant is particulate.
11. Composition according to claim 7, wherein the lubricant comprises a molten and subsequently solidified particulate mixture of the at least one secondary amide and the at least one primary amide.
12. Composition according to claim 7, wherein the composition is a bonded mixture.
13. Composition according to claim 12, wherein at least one secondary amide is used as a binding agent.
14. Composition according to claim 1, wherein the iron-based particles are surrounded by an insulating inorganic coating.
15. Method of producing a green body comprising: compacting the powder metal composition according to claim 1 to a compacted body.
16. Method according to claim 15, further comprising a heat treatment or sintering step.
17. Method of producing a bonded iron-based powder composition comprising: mixing an iron-based powder with at least one secondary amide according to claim 1; and heating the mixture to a temperature above the melting point of the at least one secondary amide.
18. Method according to claim 17, wherein the mixture further comprises at least one primary amide and wherein the heating temperature is lower than the melting point of the primary amide.
19. Powder metal composition according to claim 1 wherein said lubricant is capable of serving as a die wall lubricant.
20. Composition according to claim 2, wherein R.sub.1 and R.sub.2 are selected from the group consisting of alkyl and alkenyl.
ОПИСАНИЕ
The benefit is claimed under 35 U.S.C. .sctn. 119(a)-(d) of Swedish Application No. 0402239-8, filed Sep. 17, 2004 and Swedish Application No. 0500072-4, filed Jan. 12, 2005, and under 35 U.S.C. 119(e) of the U.S. Provisional Application No. 60/621,805, filed Oct. 26, 2004.
ОБЛАСТЬ ТЕХНИКИ, К КОТОРОЙ ОТНОСИТСЯ ИЗОБРЕТЕНИЕ
The present invention concerns a powder metal composition. Specifically the invention concerns a powder metal composition including a lubricant and/or binder comprising at least one secondary amide. The invention further concerns a method of producing a green body, a method of producing a bonded iron-based powder composition and use of the lubricant and/or binder.
ПРЕДПОСЫЛКИ СОЗДАНИЯ ИЗОБРЕТЕНИЯ
Metal powders are used in industry for the manufacture of metal products by compacting the metal powder in a die under high pressures, ejecting the compact from the die and optionally sintering the product. In the majority of powder metallurgical (PM) applications a lubricant is comprised in the powder in order to provide the necessary lubrication action between powder particles during compaction and between the die and the compact during ejection from the die. Lubrication achieved by a lubricant included in the metal powder is referred to as internal lubrication in contrast to external lubrication, which is achieved by applying a lubricant to the walls of the die, wherein the powder is compacted. Insufficient lubrication during ejection results in excessive friction between the compact and the die resulting in high ejection energies and damage of die surfaces and product surfaces.
Internal lubrication is achieved by using special lubricants. Normally these lubricants are admixed with the iron or iron-based powder in the form of a powder. Some lubricants may also be used for binding additives, such as e.g. alloying elements, to the iron or iron-based particles. In these cases the lubricants thus work as binding agents and reduce or eliminate segregation of the additives during shipping and handling.
Commonly used lubricants for PM applications are metal soaps, such as lithium and zinc stearate. A disadvantage with this type of lubricant is that oxides of the metals in the lubricant contaminate the inside of the sintering furnace as a result of release of metals from the lubricant during sintering, another problem is that stains may be formed on the component after sintering. Another commonly used lubricant is ethylene bis stearamide (EBS). Stains may also be formed on the component after sintering when using this lubricant, but to a lesser extent compared with using e.g. zinc stearate. As lubricants strongly affect compacting and sintering properties of metal powders optimization of amount, composition and structure of the used lubricant is of vital importance to obtain high and consistent densities and good surface finishes of the produced parts.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a new powder metal composition comprising a lubricant and/or binder that reduces or eliminates the problems with high ejection forces and stained surfaces of the sintered parts.
Further objects of the invention are to provide a method of producing compacted products and sintered or heat treated parts, a method of producing a bonded powder metal composition and use of the lubricant and/or binder.
СУЩНОСТЬ ИЗОБРЕТЕНИЯ
These objects are accomplished by a powder metal composition comprising an iron based powder and a lubricant and/or binder comprising at least one secondary amide. The invention further concerns a method of producing a green body by subjecting the above mentioned composition to compaction.
The method of producing a bonded powder metal composition comprises: mixing an iron-based powder with at least one secondary amide and heating the mixture to a temperature above the melting point of the at least one secondary amide.
Additionally, the invention concerns the use of the at least one secondary amide as a lubricating and/or binding agent for iron-based powders, and its use for die wall lubrication.
ПОДРОБНОЕ ОПИСАНИЕ ИЗОБРЕТЕНИЯ
The lubricant and/or binder in the powder metal composition according to the invention is at least one secondary amide that may be defined by the general formula: R.sub.1--NH--CO--R.sub.2, wherein the R.sub.1- and R.sub.2-groups, which may be the same or different, are straight or branched, saturated or unsaturated aliphatic hydrocarbon groups.
Preferably, R.sub.1 and R.sub.2 independently include 10 to 24 carbon atoms.
Preferably R.sub.1 and R.sub.2 are selected from the group consisting of alkyl and alkenyl.
The alkyl groups may be chosen from decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl, docosyl, tricosyl, tetracosyl.
The alkenyl groups may be chosen from decenyl, undecenyl, dodecenyl, tridecenyl, tetradecenyl, pentadecenyl, hexadecenyl, heptadecenyl, octadecenyl, nonadecenyl, eicosenyl, heneicosenyl, docosenyl, tricosenyl, tetracosenyl.
Examples of preferred secondary amides are shown in Table 1.
TABLE-US-00001 TABLE 1 General formula: R.sub.1--NH--CO--R.sub.2 R.sub.1 no R.sub.2 no of C- of C- atoms atoms R.sub.1 R.sub.2 Chemical name Chemical structure Common name 18 15 Octadecenyl Pentadecyl Octadecenylhexa- CH.sub.3(CH.sub.2).sub.7HC.d- bd.CH(CH.sub.2).sub.8NHCO(CH.sub.2).sub.14CH.sub.4 Oleyl palmita- decaneamide mide 18 17 Octadecyl Heptadecyl Octadecylocta- CH.sub.3(CH.sub.2).sub.17NHCO(CH- .sub.2).sub.16CH.sub.3 Stearyl decaneamide stearamide 18 17 Octadecenyl Heptadecyl Octadecenylocta- CH.sub.3(CH.sub.2).sub.7HC.d- bd.CH(CH.sub.2).sub.8NHCO(CH.sub.2).sub.16CH.sub.3 Oleyl steara- decaneamide mide 18 17 Octadecyl Heptadecenyl Octadecylocta- CH.sub.3(CH.sub.2).sub.17NHCO(- CH.sub.2).sub.7HC.dbd.CH(CH.sub.2).sub.7CH.sub.3 Stearyl deceneneamide oleamide 18 17 Octadecenyl Heptadecenyl Octadecenylocta- CH.sub.3(CH.sub.2).sub.7HC- .dbd.CH(CH.sub.2).sub.8NHCO(CH.sub.2).sub.7HC.dbd.CH(CH.sub.2).sub.7CH.sub- .3 Oleyl oleamide deceneneamide 18 21 Octadecyl Heneicocenyl Octadecyldoco- CH.sub.3(CH.sub.2).sub.17NHCO(- CH.sub.2).sub.11HC.dbd.CH(CH.sub.2).sub.7CH.sub.3 Stearyl ceneneamide erucamide 18 21 Octadecenyl Heneicocenyl Octadecenylocta- CH.sub.3(CH.sub.2).sub.7HC- .dbd.CH(CH.sub.2).sub.8NHCO(CH.sub.2).sub.11HC.dbd.CH(CH.sub.2).sub.7CH.su- b.3 Oleyl eruca- deceneneamide mide 22 17 Dococenyl Heptadecyl Dococenylocta- CH.sub.3(CH.sub.2).sub.7HC.dbd.C- H(CH.sub.2).sub.12NHCO(CH.sub.2).sub.16CH.sub.4 Erucyl decaneamide stearamide 22 17 Dococenyl Heptadecenyl Dococenylocta- CH.sub.3(CH.sub.2).sub.7HC.dbd- .CH(CH.sub.2).sub.12NHCO(CH.sub.2).sub.7HC.dbd.CH(CH.sub.2).sub.7CH.sub.3 - Erucyl olea- deceneneamide mide 22 21 Dococenyl Heneicocenyl Dococenyldoco- CH.sub.3(CH.sub.2).sub.7HC.dbd- .CH(CH.sub.2).sub.12NHCO(CH2).sub.11HC.dbd.CH(CH2).sub.7CH.sub.3 Erucyl ceneneamide erucamide 24 11 Tetracosyl Undecyl Tetracocyldo- CH.sub.3(CH.sub.2).sub.23NHCO(CH2).- sub.10CH.sub.3 Lignoceryl decaneamide lauramide 24 17 Tetracosyl Heptadecyl Tetracocylocta- CH.sub.3(CH.sub.2).sub.23NHCO(- CH.sub.2).sub.16CH.sub.3 Lignoceryl decaneamide stearamide
The amount of secondary amides may constitute 0.05-2.0% by weight of the powder metal composition, preferably 0.05-1.0% by weight.
One embodiment of the invention concerns a powder metal composition comprising a lubricant and/or binder further comprising at least one primary amide in addition to the at least one secondary amide. The at least one primary amide is preferably a saturated or unsaturated fatty acid amide having 12-24, preferably 14-22 C-atoms and most preferably 16-22 C-atoms.
Especially preferred primary amides are stearic acid amide (stearamide), behenic acid amide (behenamide), eurcic acid amide (erucamide), palmitic acid amide (palmitamide) and arachidic acid amide (arachidamide).
The primary and secondary amides according to the invention are either commercially obtainable or may be produced from commercially obtainable material by the use of processes well known in the art.
The amount of primary and secondary amides may constitute a total of 0.05-2.0% by weight of the powder metal composition, preferably 0.05-1.0% by weight.
The amount of the at least one primary amide may be 0.05-1.0% by weight and the amount of the at least one secondary amide may be 0.05-1.0% by weight for the embodiment of the invention comprising both types of amides.
The lubricant and/or binder may be added to the powder metal composition in the form of solid particles of each amide. The average particle size may vary, but is preferably less than 150 .mu.m.
Alternatively, the lubricant and/or binder may be added to the powder metal composition as a molten and subsequently solidified particulate mixture of the amides. This may be accomplished by mixing the amides in a predetermined ratio, the mixture is then melted, cooled and subsequently milled to a lubricant powder.
The at least one secondary amide according to the invention may be used as a binder for obtaining a bonded mixture, wherein optional alloying elements and the at least one secondary amide are bonded to the iron-based powder. This may be achieved by mixing an iron-based powder with at least one secondary amide according to the invention, and heating the mixture to a temperature above the melting point of the at least one secondary amide. At least one primary amide may further be mixed into the above mentioned mixture and the heating temperature may then be lower than the melting point of the primary amide.
Apart from the lubricant and/or binder disclosed above, the powder metal composition according to the invention may, if so desired, contain other lubricants, such as zinc stearate, lithium stearate, EBS etc.
To accomplish a bonding of the powder metal composition according to the invention other types of bonding systems may be used such as alkydes, cellulose ester resins, hydroxyalkyl cellulose resins having 1-4 carbon atoms in the alkyl group, or thermoplastic phenolic resins.
As used in the description and the appended claims, the expression "iron-based" powder encompasses powder essentially made up of pure iron, iron powder that has been pre-alloyed with other elements improving the strength, the hardening properties, the electromagnetic properties or other desirable properties of the end products and particles of iron mixed with particles of such alloying elements (diffusion annealed mixture or purely mechanical mixture). Examples of alloying elements are copper, molybdenum, chromium, manganese, phosphorous, carbon in the form of graphite, nickel, silicon, boron, vanadium, titanium, aluminium, cobalt and tungsten, which are used either separately or in combination, e.g. in the form of compounds (Fe.sub.3P and FeMo).
The iron based powders may be used for the preparation of soft magnetic parts and may, for this application, be electrically insulated. Electrical insulation of the powder particles may be made of an inorganic material. Especially suitable are the type of insulation disclosed in the U.S. Pat. No. 6,348,265, which concerns particles of a base powder consisting of essentially pure iron having an insulating oxygen- and phosphorus-containing barrier. Insulated powder particles are available as Somaloy.TM. 500 and 550 from Hoganas AB, Sweden.
Apart from the iron-based powder and the lubricant and/or binder, the powder metal composition according to the invention may contain one or more additives selected from the group consisting of processing aids and hard phases.
The processing aids used in the powder metal composition may consist of talc, forsterite, manganese sulphide, sulphur, molybdenum disulphide, boron nitride, tellurium, selenium, barium difluoride and calcium difluoride, which are used either separately or in combination.
The hard phases used in the powder metal composition may consist of carbides of tungsten, vanadium, molybdenum, chromium, Al.sub.2O.sub.3, B.sub.4C and various ceramic materials.
The invention further concerns a method of producing a green body comprising: compacting the powder metal composition according to the invention to a compacted body, wherein the composition comprises an iron based powder and a lubricant and/or binder comprising at least one secondary amide having the general formula: R.sub.1--NH--CO--R2, wherein R.sub.1 and R.sub.2 are the same or different, straight or branched, saturated or unsaturated aliphatic hydrocarbon groups. The compacted body may be sintered or heat-treated.
With the aid of conventional techniques, the iron-based powder, the lubricant and/or binder and optional additives may be mixed to a substantially homogeneous powder composition before the compaction step.
The powder metal composition and/or the die may be preheated before the compaction.
The invention further concerns the use of at least one secondary amide, defined as above, as a lubricating and/or binding agent for iron or iron based powders.
A further embodiment of the invention concerns the use of at least one secondary amide, defined as above, as a die wall lubricant.
DETAILED DESCRIPTION OF THE FIGURE
FIG. 1 shows stain formation of components after sintering due to the use of different lubricants. 1a) Ethylene bisstearamide (EBS); 1b) Oleyl palmitamide (a secondary amide according to the invention).
The invention will now be further described with the following unlimiting examples.
ПРИМЕРЫ
In the following examples lubricants having the formulas disclosed in Table 2 below have been used.
TABLE-US-00002 TABLE 2 Chemical Amide name Structural formula* type Ref: CH.sub.3(CH.sub.2).sub.16CONH(CH.sub.2).sub.2NHCO(CH.sub.2).sub.16CH.- sub.3 bis amide Ethylene bis stearamide (EBS) Stearamide CH.sub.3(CH.sub.2).sub.16CONH.sub.2 Primary (S) Arachid- CH.sub.3(CH.sub.2).sub.18CONH.sub.2 Primary amide (A) Erucamide CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.11CONH.sub.2 Pri- mary (E) Behenamide CH.sub.3(CH.sub.2).sub.20CONH.sub.2 Primary (B) Stearyl R1 = C18:0 R2 = C17:0 Secondary Stearamide (SS) Erucyl R1 = C22:1 R2 = C17:0 Secondary Stearamide (ES) Oleyl R1 = C18:1 R2 = C15:0 Secondary Palmitamide (OP) Stearyl R.sub.1 = C18:0 R.sub.2 = C21:1 secondary Erucamide (SE) Oleyl R.sub.1 = C18:1 R.sub.2 = C17:0 secondary Stearamide (OS) Stearyl R = C18:0 R.sub.2 = C17:1 secondary Oleamide (SO) *The structural formulas for the secondary amides are referring to R.sub.1--NH--CO--R.sub.2 as previously described.
Example 1
This example demonstrates the lubrication properties of different secondary amides and different combinations of secondary and primary amides, which are added as a powder in iron-based powder mixes.
Base powder ASC 100.29 (available from Hoganas AB, Sweden) was mixed with 0.5% by weight of graphite (uf-4 from Kropfmuhl) and 0.8% by weight of lubricants, according to Table 3 and 4, in a Lodige mixer for 2 minutes. Ethylene bisstearamide (EBS, available as Licowax.TM. from Clariant, Germany) was used as a reference. The lubricants had a particle size less than 150 .mu.m. Compositions comprising both a secondary and a primary amide contained 50% of each amide (0.8% by weight of the total composition).
In order to measure the lubricating properties rings with an inner diameter of 45 mm, an outer diameter of 55 mm and a height of 10 mm were compacted at ambient temperature at three different compaction pressures (400, 600 and 800 MPa). During ejection of the compacted parts the ejection force was recorded. The green density of the parts was measured after ejection and the total ejection energy/enveloping area needed in order to eject the samples from the die was calculated.
The resulting ejection energies and densities are shown in Table 3 and 4. Lower ejection energies where achieved when using the powder metal composition according to the invention compared with the use of the reference composition comprising EBS.
TABLE-US-00003 TABLE 3 Densities and ejection energies (secondary amides and reference). Premixed Green Density Ejection Energy (g/cm.sup.3) (J/cm.sup.2) 400 600 800 400 600 800 Lubricant MPa MPa MPa MPa MPa MPa EBS (Ref) 6.70 7.04 7.17 19.2 26.1 28.2 SS 6.72 7.06 7.19 17.6 24.7 27.9 ES 6.78 7.12 7.23 16.3 20.3 20.8 OP 6.78 7.14 7.25 16.7 21.3 20.3 SE 6.78 7.13 7.24 16.8 21.9 21.8 OS 6.78 7.13 7.24 17.7 21.3 20.5 SO 6.79 7.13 7.23 15.9 21.4 20.4
TABLE-US-00004 TABLE 4 Densities and ejection energies (secondary + primary amides 1:1 and reference) Premixed Green Density Ejection Energy (g/cm.sup.3) (J/cm.sup.2) 400 600 800 400 600 800 Lubricant MPa MPa MPa MPa MPa MPa EBS (Ref) 6.70 7.04 7.17 19.2 26.1 28.2 SS + E 6.69 7.06 7.21 19.1 24.2 23.6 OP + S 6.70 7.06 7.19 18.2 22.1 22.3 ES + S 6.71 7.06 7.19 17.9 21.5 21.8 ES + E 6.72 7.11 7.23 17.8 20.7 19.0
Example 2
The base powder ASC 100.29 was mixed with 2% by weight of Copper (-100 .mu.m), 0.8% by weight graphite and 0.8% by weight of lubricants (a) EBS or b) oleyl palmitamide) in a Lodige mixer for 2 minutes. The lubricants had a particle size less than 150 .mu.m. In order to measure the stain formation after sintering of components, cylindrical components with a diameter of 64 mm and a height of 32 mm were compacted to a green density of 7.1 g/cm.sup.3 at ambient temperature. The weight of one cylinder was 700 g. The components were sintered in an atmosphere containing 90/10 N.sub.2/H.sub.2 at 1120.degree. C. for 15 minutes. Photos of the components are shown in FIG. 1a) Ethylene bisstearamide (EBS) and 1b) oleyl palmitamide, in which FIG. 1a) show stain formation in contrast to the part produced from the powder composition according to the present invention (1b) which has no stains.
Example 3
This example demonstrates the lubrication properties of different combinations of secondary and primary amides, which have been melted together, cooled and milled before being mixed with iron-based powder mixes.
The lubricant combinations were made according to following method: The mixed lubricants, 50% primary and 50% secondary amide, were melted together at 80-110.degree. C. and then cooled. Then the materials were milled to a mean particle size of below 150 .mu.m.
The base powder ASC100.29 was mixed with 0.5% by weight of graphite and 0.8% by weight of lubricant combination (see Table 5), in a Lodige mixer for 2 minutes. In order to measure the lubricating properties rings with inner diameter of 45 mm, outer diameter 55 mm and a height 10 mm were compacted at three different compaction pressures, 400, 600 and 800 MPa at ambient temperature. The resulting ejection energies and densities are shown in Table 5.
TABLE-US-00005 TABLE 5 Densities and ejection energies (secondary + primary amides and reference). Melted and solidified Green Density Ejection Energy (g/cm.sup.3) (J/cm.sup.2) 400 600 800 400 600 800 Lubricant MPa MPa MPa MPa MPa MPa EBS (Ref) 6.70 7.04 7.17 19.2 26.1 28.2 SS + E 6.70 7.06 7.20 18.8 22.4 22.6 OP + S 6.71 7.07 7.20 18.5 23.2 24.4 ES + S 6.71 7.07 7.20 18.9 22.7 23.5 ES + E 6.70 7.07 7.20 17.2 19.8 18.0
When comparing the test results in Table 5 it can be seen that samples produced from the powder metal composition according to the invention show lower ejection energies compared to samples produced from the known lubricant EBS.
Example 4
This example demonstrates the lubricating and binding properties of different combinations of amides in powder metal compositions.
The lubricants had a particle size less than 150 .mu.m. The base powder ASC100.29 was mixed with 2% by weight Cu-100, 0.8% by weight of graphite and 0,8% by weight of lubricant/binder combination according to Table 6, in a Lodige mixer for 2 minutes. The mixture with EBS was kept as reference while the mixtures comprising amides were heated to a temperature above the melting point of the secondary amide but below the melting point of the primary amide during mixing in another mixer followed by cooling to accomplish bonding of the additives to the iron powder. In this mixture the secondary amide will thus act as a binder and the primary amide will act as a lubricant. The melting temperatures of the amides are disclosed in Table 7.
Further, the ejection energy was measured on rings having an outer diameter of 55 mm and an inner diameter of 45 mm and a height of 10 mm compacted at three different compaction pressures, 400, 600 and 800 MPa at ambient temperature. The resulting ejection energies and green densities are shown in Table 8.
TABLE-US-00006 TABLE 6 Lubricant/binder combinations for example 4. Secondary amide Primary amide 0.2% by weight 0.6% by wt ES B OP S OP B EBS (Ref 1) (0.8% by wt)
TABLE-US-00007 TABLE 7 Melting temperatures of the amides. Amide Melting temperature(.degree. C.) ES 72.9 OP 66.9 B 101.9 S 106.6
TABLE-US-00008 TABLE 8 Densities and ejection energies (primary + secondary amides and reference). Melt bonded Green Density Ejection Energy (g/cm.sup.3) (J/cm.sup.2) 400 600 800 400 600 800 Binder/Lubricant MPa MPa MPa MPa MPa MPa ES + B 6.75 7.06 7.19 18.5 24.6 28.1 OP + S 6.73 7.09 7.18 19.3 26.6 28.3 OP + B 6.77 7.08 7.19 19.9 25.3 27.1 EBS (Ref) 6.74 7.06 7.17 21.4 30.8 32.8
Samples produced with the aid of the lubricant/binder according to the invention show lower ejection energies compared to samples produced with the lubricant used as reference, i.e. EBS. Use of the powder composition comprising the lubricant/binder according to the invention resulted in compacted sintered parts (sintered in 90/10 N.sub.2/H.sub.2 at 1120.degree. C. for 30 minutes) with excellent surface finishes, i.e. essentially without scratches and no stain formation.
Example 5
A coarse soft magnetic iron-based powder, wherein the particles are surrounded by an inorganic insulation was mixed with secondary amide lubricant according to Table 9. As reference lubricants the known substances Zinc-stearate and EBS were used. The particle size distribution of the used iron-based powder is disclosed in Table 10.
The obtained mixes were transferred to a die and compacted into cylindrical test samples (50 g) having a diameter of 25 mm, in an uniaxial press movement at a compaction pressure of 1100 MPa. The die material used was conventional tool steel. During ejection of the compacted samples the ejection force was recorded. The total ejection energy/enveloping area needed in order to eject the samples from the die was calculated.
The results of the measurements regarding ejection energy, green density and surface appearance in the green state are shown in Table 9. Use of the powder metal compositions according to the invention resulted in that compacted components with excellent surface appearance and lower ejection energies were achieved compared with the reference compositions.
TABLE-US-00009 TABLE 9 Densities, ejection energies and surface appearance. Ejection Green Lubricant energy Density Surface Mix no (0.2 wt %) (J/cm.sup.2) (g/cm.sup.3) appearance 1 ES 76 7.65 Perfect 2 SE 71 7.66 Perfect 3 SS 78 7.63 Perfect 4 OP 76 7.66 Perfect Ref 1 Zinc stearate 117 7.66 Not acceptable Ref 2 EBS 113 7.64 Perfect
TABLE-US-00010 TABLE 10 Particle size Coarse powder (.mu.m) (wt %) >425 0.1 425-212 64.2 212-150 34.1 150-106 1.1 106-75 0.3 45-75 0.2 <45 0
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