Apex Advanced Technologies, Inc. Presented by: Dennis Hammond Optimizing Lubrication To Maximize Density and Minimize Ejection Forces

Presentation Outline Overview of Superlube™ characteristics Theory of maximizing density and minimizing ejection forces Methods used to optimize lubrication Applications – Minimizing ejection for large or complicated parts at a G.D. of 7.0 g/cc –Maximizing density and minimizing ejection forces for pure iron and performance alloys Conclusions

Superlube™ Characteristics Lubricant enters with the powdered metal as a solid, 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, 7.2 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 No special setup required Stroke rate can be increased Compressibility curve can be modified to allow larger parts or lower tonnage in the same press Tool wear improved 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 compact 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

Theory of Optimization Maximum green density is fixed by the compressibility of the base metal, volume of components added, and TSI Excellent lubrication allows the user to approach the maximum green density for a composition at a given TSI applied

Theory Cont. Using an internal Apex method, we can determine the maximum practical green density of a base metal at a given TSI Theoretical density minus practical density = volume of open space By targeting to fill this open space with the volume of the components in the mix, we have a basis for calculation of total volume % achieved

Maximum Compressibility of Various Base Metals 40TSI50 TSI60TSI A-1000A A-1000B A-1000C A-85HP A-737SH

Maximum Compressibility of Various Base Metals 40 TSI50TSI60 TSI ASC ABC Astaloy 85 Mo Astaloy Mo Astaloy CrL

Maximum Compressibility of Various Base Metals 40TSI50TSI60TSI Astaloy CrM Atomet Atomet 1001HP Atomet Atomet

Theory Cont. Mobile lubricant is pressed to the die wall due to the collapse of the pores or closing of the open space as the base metal is compressed Serves as an internal and die wall lubricant at the same time

Theory Cont. 98% to 100% volume fill has been found to work effectively 99%to 99.5% volume fill is an optimum target to achieve max. green density and minimum ejection while accommodating normal production variability Predictability is robust and has been proven in many production examples

FLN TSI/ G.D./ Vol.%.35% Superlube™ TSIG.D. g/ccVol.%

Theory Cont. Some formulas need to have the volume adjusted upward to take maximum advantage of the lubricant An Apex enhancer can be used effectively to make volume adjustments Key issues are, the volume contribution of components needed and the desired density

IngredientsMix % Specific Gravity Volume Contribu tion Volume Contribution by % Iron97.06% % Nickel1.99% % Graphite0.60% % PS1000b0.35% % Max Iron % 93.75% Non-Iron %6.33% Max Practical Green Density 7.35 Volume Achieved: % Common Formulation for FN-0205

Common Formulations Calculated G/D,TSI, A-1000C,.35% Superlube™ FN-0205: – 99% vol. 7.31g/cc, 46 TSI –100%vol. 7.39g/cc, 52 TSI FN-0208: – 99% vol g/cc, 41TSI –100% vol g/cc, 45TSI FC-0208: – 99% vol g/cc, 41TSI –100% vol g/cc, 45TSI

Enhancer Characteristics Clean burning, no ash Primary function to fill space, secondary lubrication Needs to deform and slide with the metal and lubricant movement Helps to maintain green strength Compatible with mixing, compaction and processing Favorable cost, specific gravity ratio

Applications A tall or complex part of lower G.D to 7.1 g/cc can be made successfully by adjusting the volume fill upward by using an enhancer. Benefits include lowering ejection forces, minimized die wear, part breakage, internal cracking or lower compaction tonnage to achieve the desired G.D.

Lube (WT. %).35 Enhancer (WT. %)

Applications cont. A pure iron part can be made using the same concept, % volume fill pressed to the desired TSI A-1000C was filled with a combination of Superlube™ and Apex Enhancer at various volume %, ejection (peak and slip) were measured as well as density Possible applications - magnetic parts, etc

A-1000C Comparison Acrawax versus Apex 60TSI Wt %Vol.%Peak LbF Slide LbF Acrawax.51%98.56% Apex.35% lube.14% enhancer.49%98.56% Acrawax.71%100% Apex.35% lube.31% enhancer.66%100%

High Density Applications High density parts can be made by using the lubricant alone or with small amounts of enhancer Many applications are running in production at g/cc Lubricant use level ranges from 0.27% to 0.45% for steel parts

High Density Applications Cont. FC-0208 NAH ABC , 0.4 wt% lube, 9# part, 54 mm height, 7.2 g/cc, 45 TSI, 99.3%volume, lowered press TSI FC-0208 NAH ABC , 0.4% lube, 40 mm height, 51 mm O.D. 7.3 g/cc, 55 TSI 99.9% volume, large part, high density

High Density Applications Cont. FLC-4608, A-737SH, 0.45 wt% lube, 50 mm height, 51mm O.D. gear, 7.2 g/cc, 51TSI, 99.4% volume, large part, high density Astaloy Mo, 2% Ni, 0.3% Graphite, 0.35% lube, 0.15% enhancer, 20 mm height, 7.27 g/cc, 49TSI, multi-level with hole 99.0% volume fill

High Density Applications Cont. FLN2-4405, A-85HP 0.35% lube g/cc, 49-52TSI, 6mm - 51mm height, 14 applications helical gear, straight gears, multi- level parts, counter bores, ~ % volume fill A-85HP,2% nickel, 0.35% lube,.25% graphite,0.15% enhancer, 7.3 g/cc, 51TSI, 25 mm height, gear, 99.5% volume fill, elimination of double press

High Density Applications Above Target Range Excellent Lubricity with.25-.4% High Density 7.25 g/cc and above Metal restricted from maximum compressibility Reduced hydrostatic effect Predictability of density achievable but TSI predictions are difficult Formulas with 3% additions and higher are most likely to be over 100% fill

Application Summary High Density g/cc Elimination of double press, double sinter Highly efficient, cost effective copper infiltration Elimination of cracks, parts g/cc Minimization of ejection problems, g/cc Minimization of die wear, g/cc Improved part performance and surface finish High nickel based parts without blistering

Lube and Density Prediction By knowing the compressibility of the metal involved, the components, the part length, size, and the desired density, we can calculate the lube or enhancer needed From this calculation, achievable density verses TSI can be predicted Predictability has been robust and a very viable tool for optimizing, new part development, and problem solving

Conclusions Maximum density and minimum ejection forces are not exclusive to each other, they can be obtained at the same time A lubricant that transforms from a solid to liquid changes the rules compared to conventional lubricants Compressibility of the base metals varies significantly, and it is a critical factor in the results achievable

Conclusions Cont. High density g/cc can be achieved with no special equipment or procedures with good ejection characteristics Lower density can be successfully made with lower tonnage, lower ejection forces, and good green strength Desired lubrication and density are predictable using developed calculation methods

Conclusions Cont. We can approach the upper compressibility limit for the base metal at a given TSI with alloy components included By designing a lubricant system for a given application, the breadth of parts that can be made can vary from small to large, moderate to high density, and simple to complex. Theory and practice are transferable to other P/M parts Al, Brass,Bronze, and S.S.