Apex Advanced Technologies, Inc. Presented by: Dennis Hammond Contributor Richard Phillips Using a highly effective lubricant in combination with a polymeric additive to minimize cracking and address other process related problems

Presentation Outline Overview of Superlube™, key characteristics Overview of Enhancer and use Cracks/improved compactabilty Other processing problems Conclusions

Superlube™ Characteristics Lubricant enters with the powdered metal as a solid. Then transforms from a solid to a viscous liquid with shear, temperature, and pressure in the press Lubricant shear thins directly with shear stress Direct results from solid to liquid transformation –High density achievable to 7.4 g/cc –Low use levels required - typical 0.4% or less –Excellent lubricity - film of viscous liquid versus slide on a solid particle

Direct results Up to 50% reduction in ejection force Tool wear decreased due to better lubrication and/or lowering of tonnage Surface finish improved Improved physical properties of final part by %

Direct Results Cont. Powder movement to equalize green density, near hydrostatic conditions in compaction ( vol. %) Minimization of density gradients in the part Elimination of micro-cracking Reduces the risk of molding cracks Staggered decomposition in burn off Excellent dimensional stability of sintered parts

Enhancer Characteristics Clean burning, no ash Primary function is to occupy space, secondary is lubrication Needs to deform with no interference to metal compressibility up to 100% vol. Helps to improve green strength up to 100%- improved crack resistance Compatible with mixing, compaction and processing Favorable cost / specific gravity ratio

Methods Used Predictable method based on calculation to optimize lubrication using lubricant and enhancer, target Vol. %, near hydrostatic conditions Lubricant functions as die wall and internal lubricant simultaneously Enhancer used to occupy space, deform under load to enhance green strength

Cracks A crack can be defined as a break in interparticle bond between powder particles The bond may have been broken during processing or may have never been formed A major issue in P/M processing Once formed cannot be fixed

Cracks Root Causes Improper material composition Interparticle side shifting action Improper elastic strain release High tensile/shear stress

The Common Cracks in Green P/M Compacts 59 case studies of parts When cracks were formed - In 19 cases during compaction - In 43 cases during ejection Materials solutions - 18 cases increased green strength - 11 cases better lubrication - 4 cases improved powder compressibility - 2 cases better uniformity in compact - 2 cases improved handling

Crack Causes, Material Controlled High ejection load – better lubrication Low green strength - increase up to 100% Density gradients - near hydrostatic, limited lateral movement, 99% vol. Non-uniform porosity - small uniform pores Over compaction - movement in transition areas

Green Strength Green strength increase directly with increased G.D. The more lubricant, the worse the green strength Green strength dependent on particle shape, irregularity and hardness Green strength dependent on type and amount of solids in the P/M mix

Green Strength Superlube™ is squeezed from between the particle surfaces Enhancer is deformed for best fit The combination gives a unique mix that allows for high green strength as well as excellent lubrication Combination used to achieve vol. % at target density, the higher the density or the more volume occupied the less Enhancer is used

Medium Density/ With Enhancer, Crack Elimination FN-0205,.4%lube,.4% enhancer, gear with spokes / hub ~4inch O.D; ~1.75inch height, 7.0 g/cc, driver crack elimination, 98% volume at density FC-0208,.4% lube,.25% enhancer, multi-level part, 2 inches height transition to.5 inches, 7.0 g/cc driver crack elimination, 99% volume at density

Medium Density/ With Enhancer, Crack Elimination Proprietary formula,.4% lube,.35% enhancer, large part ~ 6.5 lbs, sprocket 7.0 g/cc crack elimination, 50% reduction in ejection forces, 99% volume at density Proprietary formula,.4% lube,.25% enhancer, large 4 level, 5 in. O.D; 2.25 in. high, 2.5 LBS, 7.05 g/cc, crack elimination plus the ability to eject from the die, 99% volume

Processing Problems Addressed with Superlube™/ Enhancer Dimensional stability Die Wear Highly effective copper infiltration Elimination of blistering on high nickel formulas

Dimensional Stability Dimensional Stability - uniform, predictable size change after sintering Minimization of density gradients in the part - near hydrostatic conditions Particles rearrange during full compaction cycle for best fit - small uniform pores Dimensional stability plus superior physical properties; fatigue, strength, hardness

Medium Density, Blistering, Die Wear, Gradient FN-0205,.3% lube,.45% enhancer,.7 inch O.D; 1.25 inch height, 7.05 g/cc, driver blistering problems, 98% volume 45P base,.4% lube,.35% enhancer, 3inch height, 7.1 g/cc, driver die wear, 99% volume 45P base,.4% lube,.25% enhancer, 1.75 inch height, 7.17 g/cc, driver high density/density split minimization, 99% volume

Medium Density, Gradient Infiltration FN-0205,.4% lube,.25% enhancer, inside gear ~4inch O.D. ~ 2inch height, 7.1 g/cc ~35 TSI, driver density split, dimensional stability, 98% volume at density FLC 4608,.35% lube, gear 1 inch O.D;.65 inch height, 7.2 g/cc, 98.5% volume, copper infiltrated, 7.67g/cc

Conclusions & Customer Benefits

High Density Density better than hot, warm compaction and die wall lubrication Superior physical properties Elimination of double press / double sinter No special equipment or setup required Increased process capability

Crack Elimination/ Minimization g/cc density range Lower ejection – up to 50%, lower stress on part Higher green strength, up to 100% Near hydrostatic conditions - minimize over compaction in transition areas Minimization of gradients Small uniform porosity Elimination of micro - cracking

Increased Compressibility Compressibility up to 30% higher Larger parts in an existing press Less stress on tools Less wear on tools Extended life of press components

Environmentally Friendly No metallic Stearates Staggered burn out - less gas out at one time Pores are not closed - better out gassing - near hydrostatic conditions Improved furnace though put

Better Lubrication Sliding on film of viscous liquid / verses solid particle Tool wear >25% increased life Slide forces significantly lower than with conventional solid lubricants – as much as 50%

Predictable Lubrication needs are known before going on the press Density is calculated before going on the press Press tonnage is known before going on the press Streamlines the process of quotation, development and problem solving

Final Part Physical properties increased %: fatigue, hardness, and strength Dimensional stability is excellent Less rejects or scrap Less chance of surface blemishes Secondary operations with improved process capability due to sintered part consistency