Manganese as a primary alloying element Dennis Hammond –Apex Advanced Technologies Richard R. Phillips – Engineered Pressed Materials

Manganese Background  Manganese metal admixed subject to Hydrolysis, oxidation in P/M application  Manganese as a pre-alloy, hard to compress, limited use levels  Ferro Manganese abrasive, patents  Highest performance alloying element- strength, hardenability  Previous work demonstrated feasibility of using Manganese metal admixed both as a sinter hardened and case hardened lean formulations

Manganese Background Cont.  Manganese as an admix demonstrated feasibility in multiple production furnaces in previous work  Manganese coated for protection from hydrolysis and oxidation during blending, storage and handling, supplied as master batch  Press conditions developed for maximizing protection during de-lubing and sintering

Key Features Additive/Lubricant Master Batch  Calculations for feasibility of density, desired lubrication, and needed additives  Target volume % of theoretical at target green density  Need for a green compact free of density gradients, semi-hydrostatic  Need for excellent lubrication, Apex Superlube®  Need for mobile lubricant to achieve best fit of metal particles during compaction and spread of additives

Key Features Additive/Lubricant Master Batch  Need for excellent distribution and dispersion of additives in a segregation free powder mix and compact  Protection of reactive additives by coating particles  Master batch includes all additives including proprietary additives, pre-mixed and screened, ready to mix with iron powder for easy mixing

Test Matrix for evaluation  Fixed Density -7.25g/cc green  Fixed Carbon- 0.3%  Compressible iron- AT1001HP  Mn content- 0%, 0.5%, 0.75%, 1%,1.5%, 2%  Sintering- in various production furnaces, conventional gas 2050F, rapid cool 2050F and 2265F, rapid cool vacuum 2265F and 2350F

Test Matrix for evaluation  Heat treatment-.6%carbon potential, temper at 350F  Test- carbon content, size change, sintered density, TRS strength, hardness, and Impact

Carbon content after Sintering 2050 F slow cool % Mn% C before sinter% C after Sinter 00.3%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 loss  Less losses of Graphite with Manganese than with plain iron  Manganese well protected using this coating technology

Conclusions- density and size  Higher sintering temperature results in higher sintered density  Increased Mn leads to increased growth  Sintering1% Mn at 2265F/1240C appears optimum for density  0.75 to1% Mn gives near neutral growth <0.1% change considered to be ideal

Conclusions –TRS Strength  0.75% Mn appears to be optimum for TRS  Near 100% improvement in strength at higher temperatures over 2050F/1121C  Heat treated 0.5% Mn gives optimum results

Conclusions- hardness  As sintered general improvement in hardness with increased Mn content  Hardness after heat treatment no significant improvement after 0.75% Mn  Hardness after heat treatment with 0.75% Mn all 44 HRC and above

Conclusions -Impact  0.5% -0.75% Mn optimum for impact  Fast cooling gas furnace gave the best impact  Mn coupled with higher temperature sintering can give dramatic improvements of impact strength

Over all conclusions  Elemental Mn can be protected and effectively used in powdered metal  No significant carbon loss  No compromise of compressibility  Properties can generally be improved with Mn levels of 0.5 to 1%  Increased sintering temperature gives improved properties with Mn containing formulas

Over all conclusions, Cont.  Mn can be a cost effective alloying element  Mn can be used in powdered metal on convention sintering furnaces  Mn can be substituted for other more costly alloying elements

Acknowledgments  Horizon, Ridgway Powder Metals, Engineered Pressed Materials, Advantage Metal Powders, Product Assurance