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058 - Properties of Ferromagnetic Powders
John Johnson, FAPMI, Novamet/Ultra Fine Specialty Products

Ferromagnetic powders are used extensively in electronic applications and for magnetic shielding, but limited information is available on their magnetic properties prior to their use in a component or coating. Vibrating sample magnetometry (VSM) is a well-established method for the magnetic characterization of powders. In this work, VSM is used to measure the permeability, coercivity, saturation, and remanence of several ferromagnetic powders including iron, nickel, Sendust (Fe-Si-Al), molybdenum permalloy (Ni-Fe-Mo), and permendur (Fe-Co-V). The effects of different particle size distributions and morphologies of these metal and alloy powders on their magnetic properties are also investigated.

078 - Comparison of Soft Magnetic Composites (SMC) and Lamination Assemblies
Bruce Lindsley, Hoeganaes Corporation

Lamination sheet steel used for magnetic stator cores have excellent magnetic properties within individual sheets. The comparison of these individual sheet properties, such as maximum saturation and permeability, with powder-based soft magnetic composites appears unfavorable for SMC use. The properties of lamination assemblies, however, is lower than individual sheets due to stacking factor and the presence of insulation layers. Further, it is commonly understood that these stacks tend to work best at lower frequency, whereas SMC is more suited to higher frequency. The number of direct comparisons of SMC and lamination steel stacks is limited in the literature, resulting in broad generalizations. In this study, test rings made with assemblies of two lamination steel grades and two grades of SMC will be evaluated under different test conditions. The direct comparison will enable users of the technology to understand the benefits and limitations of each approach, leading to the best engineering solutions. 

062 - The Creation of Semi-hydrostatic Environment to Reduce or Eliminate the Density Variation within a Compact 
Mihai Faroga, PMT, Stackpole International

This study will be evaluating the conditions required to create gradient-free high-density compacts. This idea goes against the common knowledge that a compact will reach the highest density within the top and bottom of the compact. Apex believed that in certain conditions, a semi-hydrostatic environment could be created in order to reduce or eliminate the density variation within a compact.
For this study, various percentages of lubricant in a blend were compared against the top, middle and bottom of a tall green ring. Furthermore, the target density impact on density variation as well as tonnage required to achieve a “gradient free” density part was evaluated. An additional approach was to establish the impact of the die temperature on the performance of the compacts. It was important to recognize the impact that iron base compressibility will have on the outcome of the data. 

113 - Effect of Chemistry and Processing on Sinter-Hardening Performance of Non-standardized Alloy Compositions
Neal Kraus,  Hoeganaes Corporation

MPIF Standard 35 Grade FL-4800 base iron is an adaptable sinter-hardenable base iron which can provide a fully martensitic structure on large cross section parts. This base material is used in a number of pre-alloyed and sinter-hardenable grades, but does not report a higher graphite composition without the addition of copper. This work will explore utilizing this base iron in a number of compositions outside of the typical standard. Mechanical properties on test bars and parts are explored.

048 - Mechanical and Dynamic Properties of Sustainable Powder Metallurgy Alloy FL-5008
Roland Warzel III, North American Höganäs Co.

Sustainability is a growing trend within society and the automotive industry. Powder Metallurgy (PM) is already recognized as a green technology which can address the sustainability requirements of current and future applications. A recently introduced lean chromium alloy was shown to provide similar mechanical performance to copper steel materials. This alloy also has a sustainability advantage over copper steels. For many applications, fatigue strength is a limiting factor and reliable fatigue data and models are important in selecting the best material system. In this paper, the mechanical properties of the recently standardized material FL-5008 will be presented. Additionally, fatigue data for the FL-5008 will be compared to copper steels and a fracture mechanics model will be presented to reliably predict the effect of density and stress concentrations on fatigue life.

024 - Metal Powder Atomization by Arc-Spray Process
Quentin Mandou, Air Liquide

With the strong expansion of metal powder related applications and more specifically additive manufacturing, powder suppliers are facing a worldwide growing demand of feedstock complying with very stringent technical specifications. Total production capacity (all applications included) is expected to reach roughly 200 kilotons per year by 2027 (source : 2023 market survey). From a metal powder producer perspective, developing alternative technologies make it possible to enlarge market opportunities while offering complementary solutions for customers. A literature review of arc-spray suggests good abilities to convert molten metal into powder. As a result, specific developments have been conducted at Air Liquide R&D on a complementary gas atomized powder manufacturing process. This work presents results obtained with an arc-spray atomizer for titanium alloy (Ti-6Al-4V) powder production with a specific focus on additive manufacturing applications. In this work, an arc-spray atomizer has been developed to demonstrate the relevance to use this technology as an efficient and agile way to produce metal powders for applications including additive manufacturing. A proper setting of the electrical parameters and atomization pressure have been developed to achieve good productivity, yields and powder quality. In addition, it has been demonstrated that this technology is relevant towards its limited floor space requirement, easy storage and varying feedstock (wires) and above all an important decrease of required energy to melt the metal which complies with carbon footprint objectives for industry. 

027 - Alloy Development for Additive Manufacturing Using Ultrasonic Atomization
Jakub Ciftci, AMAZEMET Sp. z o. o. [Ltd.]

Current methods for the production of spherical powders restrict the development of new chemical compositions dedicated to the additive manufacturing industry. This novel ultrasonic atomization process enables in-house powder production from even one gram up to a few kilograms to verify new alloys. Plasma-based ultrasonic atomization was used to manufacture spherical powder of the high-temperature alloy, while induction-based ultrasonic atomization was used to develop a low-melting alloy. Additional case studies will be presented to provide an overview of the technology possibilities.

138 - A Melt-Less Method for Making Spherical Ti Alloy Powder

Additive manufacturing (AM) is considered an energy-efficient alternative to conventional subtractive manufacturing of metals. However, the high embodied energy of the feed materials undermines the merits of energy saving in AM. Spherical Ti-6Al-4V alloy powder, widely used in AM, is commercially produced by atomizing Ti alloys made from the Kroll process. This production route incurs high energy consumption due to the low yield, the energy-intensive processes of melting and atomizing the metal into fine particles, and the production of the primary titanium metal. This paper presents a melt-less pathway, called the GSD method, for fabricating spherical Ti-6Al-4V alloy powder from low-cost feedstocks including alloy scrap or oxides. The chemical and physical properties of the fabricated powders are evaluated for AM applications. Energy consumption analysis suggests that the process has the potential to significantly reduce the energy consumption of producing titanium alloy feedstock and improve the environmental impact of AM.

145 - Effect of Novel Nano-Boronated Alloy on The Densification, Surface Morphology, Hardness and Magnetic Properties of Sintered AISI630/UNS S17400
Arun K. Chattopadhyay,  Uniformity Labs

136 - Utilization of Additive Manufacturing to Improve Performance and Business Case for Lathe Chuck Jaws
Jeff Howie ,  Nichols Portland Inc.

For “one-off” and low production volume projects, metal additive manufacturing (MAM) offers many advantages compared to traditional metal-forming and machining technologies, including superior design freedom, short lead-time from concept to build, and zero tooling investment. One area that Alpha Precision Group (APG) has benefited from these technical advantages is in the development, optimization and build of customized production machining fixtures for high-volume PM components manufacturing.  In general, MAM offers fast turnaround for progressive design iterations and optimization, which translate to improved launch readiness and cost management.  For one specific PM product family, the machining fixtures produced by MAM technology have led to improved machining process capability.  In the case of round thin-walled sintered components like gears and tone wheels, the light-weight chuck jaws have netted significant gains in the inner diameter roundness compared to traditional chuck jaws . This paper details the differences in design, build, lead-time, cost and process capability between lightweight chuck jaws produced from additive manufacturing and traditional chuck jaws produced from tool steels.

067 - C18000 for Sinter-Based Additive Manufacturing
Miranda Moschel, Kymera International

Pure copper has been receiving increased attention and development efforts within the AM community due to its high electrical and thermal conductivity. As the industry evolves, we will need to expand beyond pure copper to meet other application needs. C18000 is a precipitation hardened copper alloy that maintains a reasonable amount of electrical conductivity, but achieves much higher strengths and hardness than pure copper. Here we review results of C18000 printed on a sinter-based AM technology that achieves high density, strength, and conductivity.

510 - Understanding the Fatigue Data Required for Today's FEA Software and the Current Status of the PM Industry Development of This Data
Carl Blais, Laval University

The design cycle of new products has evolved from years to months to days with the assistance of engineering software.   A significant feature to CAE/CAD software is the material database they contain which allow designers and engineers to model the individual parts and test its ability to withstand the application before any material is cut or fabricated.  MPIF recognizes the importance of developing and verifying the material properties through Standard 35 and has also recognized the current fatigue data is not sufficient for use in CAE software.  This session is intended as a refresher/tutorial overview of the various fatigue types, specimen testing, s/n curve review and the significance, how they are applied to various part application development, and the current status of this development. The technical committees within MPIF feel it is critical to develop this data to better assist the engineering community to use PM as a preferred design solution. 

401 - Introduction to W/WC
Bernard North, North Technical Management, LLC

Since the 1923 patent and initial commercialization in 1926, cemented carbides have grown to become a family of products encompassing a broad range of compositions, geometries, and applications across multiple industries, with commercial value in excess of US$15Bn per annum and employing over 100,000 people worldwide. The presentation will summarize the most important technical developments that have been implemented over time, the technical and business reasons for the importance of these materials, and some potential game-changing future developments.

402 - Properties and Measurement Methods for Cemented Carbides
Tom Jewett, Global Tungsten & Powders Corporation

The choice of a particular grade of cemented carbide is dictated in part by the application, material being worked and environmental conditions. Those factors will in part determine what properties the cemented carbide will need to possess in order to meet operational expectations. The current presentation will focus on a review of relevant sintered properties for cemented carbides as well as the methods for carrying out the measurements. Specific properties to be examined include: hardness, coercivity, magnetic saturation, transverse rupture strength (TRS), fracture toughness and wear. The reviewed properties will further be related to performance, with regard to grade design considerations.

403 - Grade Powder Production Methods
Tom Jewett, Global Tungsten & Powders Corporation

The production of cemented carbide tools begins with the preparation of ready to press (RTP) powder. That material is a combination of the base WC powder with a metallic species such as Co or Ni, additives such as Cr3C2, VC, TaC, Nb Cor TiC and an organic binder. Properly prepared, the RTP powder will allow for precision forming of WC-based tools. RTP powder can be produced by several methods, including spray drying, vacuum drying and granulation or fluidized bed processing. The choice of method is highly dependent on the user and associated production needs. The various production techniques will be reviewed independently and a comparison of the RTP powder produced from each method will be provided.