A low Density Lubricant System with Significantly Improved Green Strength and Ejection forces Dennis Hammond Apex Advanced Technologies Cleveland, OH

Green Strength Problems Cracks from ejection Chipping Handling system damage Defects post sintering Powders that do not hold together during compaction Inverse relationship with green density 2

Mechanism of Green Strength Powder variables-geometric, intrinsic and surface related Inter-particle locking Weakest link-lubricant,oxides 3

New Lubricant System Enhancer ST Modified polymer, surface treated with a lubricant Lubricant portion allows for slippage- metal particle to metal particle Polymer portion deforms with shear Polymer simulates metal particle interlock Energy needed to deform 120 F( 49C ) to180 F (82 C) ideal part temperature 4

Stainless Steel Stainless powder is inherently on the low side of ideal for green strength Stainless re-mill difficult to press Stainless gas atomized powder not considered press able due to low green strength Low density applications are not readily pressable due to low green strength 5

6

Non-Press able Stainless Applications 316L, 5.5g/cc, special particle size, 1330 PSI, 1% Enhancer ST, in production 316L 100% re-mill, non-pressable 1% Enhancer ST, in production 316L gas atomized powder D-50, 40Micron, 50 TSI, 859 PSI green strength, 6.68g/cc, 2% Enhancer ST 8

Iron Parts Low density- low green strength, cracks, chips, handling defects etc Rising cost of sponge verses water atomized Re-mill low green strength Off grade powder –inherently low green strength

10

11

12

13

14

15

16

17

18

19

Non traditional Metals Product acts as binder Titanium CP, Titanium 6-4, Titanium Carbide, Zinc, Tungsten /Iron

Conclusions Stainless Steel P/M parts made with this product can be made having significantly higher green strength with better ejection Non typical Stainless applications can be pressed into parts-low density, gas atomized,100% re-mill Low density water atomized iron parts can be made with green strength adequate for processing

Conclusion cont. Water atomized can be substituted for sponge in some applications and can have adequate green strength, with better ejection and lower compressibility than sponge Copper base metal powder can have excellent green strength and lower ejection Non traditional powders can be processed

Conclusion cont. Zinc Stearate can be eliminated by using this product with better compressibility, lower ejection, and higher green strength without environmental issues A.D is not as good with this product as Zinc Stearate, more comparable to Acrawax. Flow is typically as good or better than either product

Conclusions Cont. A.D. can be improved with the co- addition of Zinc Stearate or Lithium Stearate 75-90% Enhancer ST 25-10% Zinc or Lithium Stearate Some loss of green strength with these additions, proportional to use E.G 10% ZnSt, 6 % decrease in G.S