Lean High Performance Alloys Containing Manganese as the Primary Alloying Element Dennis Hammond Apex Advanced Technologies LLC

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

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

Customer Goals Lower alloy cost and content Ability to be formable, e.g. roll forming the teeth of a gear Tough properties Able to be carburized, case hardened Higher density Good response to sinter hardening/with better than conventional properties Ability to get higher sintered densities than conventional sinter hardenable products

Scope of Previous Work CCrMnNiMoG.D. g/cc A.65%.5%.6%.29%7.24 B.7%.75%.5%.1%7.25 C.8% 7.28 D.85%.75%.82%.27%7.22 E.8%.5%.9%.6%.29%7.22 F.85%.5%.75%.07%7.26 G.5%.75%.5%.1%7.27 H.5%.8%7.36 L.85%.74%.07%.27%7.23

Optimized Mn Lean Alloys MnCrMoCG.D. range Case hardenable 1%0.4% General Purpose 1%0.5%0.07 % 0.65 % Sinter Hard1%0.5%0.07 % 0.85 % High Perf. Sinter Hard 1%0.75 % 0.34 % 0.85 %

Process Conditions & Equipment Slugs 3.5 inch Dia. x.9 inch, 2 lbs, 550 ton Cincinnati press, Impact bars, 350Ton Sinterite Best press Sinterite belt furnace with turbo cooler 2050 slow cool (sc) 30min, 60 min, 2050 fast cool (fc) 30min, 60Min CM batch furnace, 2250F, 2350F (sc), annealed Abbott pusher with Varicool 2350 (fc) Heat treat 40 min., 1550F, 0.85% C, temper F

Production Example 0.75% Mn, 0.85%C, slow cooling belt furnace, 90N/10H, g/cc G.D. Copper infiltrated to7.6g/cc for threading and plating Requirements of wrought part 250 ft-lbs torque Mn alloy tested at 650 ft-lbs with easy tapping and good finish

Example Part

Conclusions Manganese primary contribution to properties Higher than normal hardness for P/M both with case hardening and sinter hardening Carbon loss normal at 2050F ( 0.05% C ) with Manganese and Carbon, higher loss with higher temperature, higher loss with higher Cr content (.12 to.2% C)