New Alloying Systems for Sintered Steels: Critical Aspects of Sintering Behavior

Oxygen-sensitive alloying elements such as Mn, Si, and Cr have a high potential for improving the properties of low alloyed sintered steels while reducing the alloying cost. However, it is necessary to find a way for avoiding, or at least minimizing, the oxidation of these elements especially during the early stages of the sintering cycle. In this study Mn, Si, and Cr were introduced in the form of a master alloy powder designed to be mixed with the iron base powder and provide the final composition of the steel during the sintering process. The reduction/oxidation phenomena taking place during the heating stage were studied by thermogravimetry, dilatometry, and mass spectroscopy, using either reducing (H2) or inert (Ar) atmospheres. The results show how the difference in chemical activity between base iron powder and master alloy causes the so called "internal-getter" effect, by which the reduction of less stable iron oxides leads to oxidation of the elements with higher affinity for oxygen. This effect can be somehow minimized when sintering in H2, since the iron oxides are reduced at lower temperatures at which the reactivity of the elements in the master alloy is lower. However, H2 concentration in the processing atmosphere needs to be carefully adapted to the specific composition of the materials being processed in order to minimize decarburization by methane formation during sintering.Höganäs AB Sweden, financial support provided through the Höganäs Chair IVPublicad

The role of oxygen transfer in sintering of low alloy steel powder compacts: a review of the "internal getter" effect

The chemical aspects of sintering have to be considered, in particular the role of oxygen. For sintered alloy steels used for highly stressed components, traditional alloy elements have been Cu, Ni and Mo, which in their oxygen affinity are very similar to the base constituent iron. Advanced alloying systems however contain Cr, Mn and/or Si. In the present study it is shown that one of the principal aspects of sintering to be considered is oxygen transfer from the base iron oxides to the alloy elements, which then form oxides that are more difficult to reduce. This process, defined as “internal gettering”, occurs both in mixed powder compacts and in prealloyed materials, although through different mechanisms. The effect can at least be alleviated by presintering in H2 in the 400°C range, part of the oxygen being removed as H2O before internal gettering becomes kinetically effective. However, in industrial practice, this collides with delubricaton. Furthermore for both alloy variants high temperature sintering is advantageous because it enhances reduction of the more stable oxides, thus eliminating the effects of internal gettering.European Union Marie Sklodowska-Curie scholarshi