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Critical Process Parameters in Large MIM Sintering Furnace!
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Contents!•! Process Control through Furnace Design!
•! Process Gas Flow Management!
•! Temperature Control!
•! Quenching Control!
•! Typical Results on 420 Stainless Steel!
•! Summary!
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Process Control - Furnace Design!Sizing!•!Work zone size of ! 36” x 36” x 48” = 36 ft3 (915 x 915 x 1,220 mm3 = 1020 liter)!•!Hearth gross load weight capacity 4,000lbs (1814kg)!
Temperature Range!•!Maximum operating temperature ! 2550ºF (1,425ºC)!•!Temperature uniformity! +/- 10ºF (+/- 5ºC)!
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Process Control - Furnace Design!Hot Zone!•!Graphite heating elements •!Front and rear elements
included for temperature uniformity!
Vacuum Level!•!Ultimate vacuum level - < 10 microns!
Graphite heating elements
Ultimate vacuum level -
•!N2, H2 and Ar partial pressure up to 13 mbar (10 torr)!
Pressure Level!•!Internal nitrogen or argon gas cooling up to 2 bar!
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Process Control - Furnace Design!
Required Features:!•!Purge gas system to
carry evaporated binder out of hot zone!
•!Water cooled/heated binder filtration system!
•!High e"cient booster and screw pumps with automated flushing system!
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Binder Removal Principle!•! E"cient binder trap
system to allow condensation of evaporated binder!
•! Dual Binder Trap to handle maximum cycles!
•! Minimum maintenance time thanks to quick exchangeable cartridge!
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Process Gas Management!POUTSIDE !
Evaporated Binder OUT!
PINSIDE ! Function!•! Poutside >
Pinside!•! Continuous
Process Gas Flow from outside hot zone to inside!
•! Inside & Outside Gas Flow independently adjustable!
•! Uniform gas flow ensures even binder evaporation!!
Results!•! No redeposition
of binder on the parts!
•! Prevention of Hot Zone contamination!
•! Prevention of binder deposition on the vessel walls!
•! Consistent Part Quality!!
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Process Gas Management!
•! During Debinding Cycle, gas is evacuated from the hot zone to the binder trap before going through the pumping system!
•! Wax is removed from the hot zone and collected in the binder trap!
Gas Evacuation Schematic: Debinding Cycle!
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Process Gas Management!
•! During Sintering Cycle, gas is evacuated from the hot zone to the pumping system!
•! Modulating valve regulates the pressure and allows a constant gas flow minimize the gas consumption!
Gas Evacuation Schematic: Sintering Cycle!
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Typical Results: Debinding E"ciency !
Load Description!•!Material: PH17-4 !
•!Part Weight: 15 grams!
•!14 Levels !
•!Total Parts per Load: 8400!
•!Load Weight: 126 Kg (brown parts only)!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Specification/Results!
•!Target Carbon: >0.04 – <.15% !
•!Average % Carbon: 0.082%!
•!Standard Deviation: 0.015 !
Typical Results: Debinding E"ciency !
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Temperature Control!
PID Settings!
•!5 Temperature Range!
•!Control of Ramping!
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Temperature Control!
DigiTrim Settings!
•! 4 Temperature Range!
•! Control Soaking !
•! Power Consumption!
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Temperature Uniformity!
500°F ! 1200°F! 2400°F!
Temperature Spread: ! 7.5°F!
Temperature Spread: ! 8.5°F!
!
Temperature Spread: !7.3°F !
All 3 temperatures were within the ±10˚F !AMS 2750E requirement !
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Uniform Cooling - Nozzles around the hot zone and front pack!All-in-One Process - Debinding, sintering, hardening & aging!Hardening - 2-bar quenching pressure and 100HP gas blower!
Quenching Control: Quenching Capability!
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Quenching Control: All-in-One Cycle!
•!Additional capability minimizing process time and cost!•!Having control of your process in-house is big advantage!
Hardening with 2-bar Gas Quench!
Aging!
Debinding ! Sintering!
0 2 4 6 10!8
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Typical Results# when following the process
parameters. !
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420 Stainless Steel – Testing Description!Load Description!
•! Part Weight: 30 grams!
•! 14 Levels & 16 Trays per Level!
•! Parts per Level: 320!
•! Total Part per Load: 4,450!
•! Load Weight: 135 Kg (brown parts only)!!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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420 Stainless Steel – Parts Map!Raw Test Data!
•! 24 Parts tested per layer!
•!6 Density Test!
•!6 Hardness Test !
•!6 Carbon % Test!
•!6 Critical Dimension Test!
•! Total 336 tested parts!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Hardness (HRC)!
420 Stainless Steel – Testing Results!Specification/Results!
•! Target Hardness: 45-49!
•! Average Hardness: 47.7HRC!
•! Standard Deviation: 0.27 !
Note: Testing procedures and results provided by Parmatech, an ATW Company
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% Carbon !
420 Stainless Steel – Testing Results!Specification/Results!
•! Target Carbon: 0.3 - 0.4% !
•! Average Carbon: 0.347%!
•! Standard Deviation: 0.012 !
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Density (g/cm3)!
420 Stainless Steel – Testing Results!Specification/Results!•!Target Density: 7.15-7.20 g/cm3 (as sintered)!
•!Average Density: 7.17g/cm3!
•!Standard Deviation: 0.006 !
•!Average Density after HIP : 7.7g/cm3!
!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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420 Stainless Steel – Testing Results!Specification/Results!
•!Target Dimension: ! .567 ± .003 !
•!Average Dimension: 0.5676!
•!Standard Deviation: 0.0005 !
Dimension Width (inches)!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Hardness (HRC)!
420 Stainless Steel – Testing Results!Repeatability !•!Target Hardness: 45-49!
•!Average Hardness:!•!Run #1: 47.7 HRC!•!Run #2: 47.7 HRC!
•!Standard Deviation: !•!Run #1: .27!•!Run #2: .45!
Max Variance: .5! Min Variance: 0!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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% Carbon !
420 Stainless Steel – Testing Results!Repeatability !•!Target Carbon: 0.3 - 0.4% !
•!Average % Carbon: !•!Run #1: 0.347!•!Run #2: 0.336!
•!Standard Deviation: !•!Run #1: 0.012!•!Run #2: 0.008!
Max Variance: 0.025! Min Variance: 0.0006!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Repeatability !•! Target Density:
7.15-7.20 g/cm3 (as sintered)!
•! Average Density (g/cm3): !•! Run #1: 7.167!•! Run #2: 7.161!
•! Standard Deviation: !•! Run #1: 0.006!•! Run #2: 0.008!
Density (g/cm3 )!
420 Stainless Steel – Testing Results!
Min Variance: 0.001! Max Variance: 0.024!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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Dimension Width (inches)!
420 Stainless Steel – Testing Results!Repeatability !•! Target Dimension : ! .567 ±.003 !•! Average Dimension
Width (inches): !•!Run #1: 0.5676!•!Run #2: 0.5656!
•! Standard Deviation: !•!Run #1: 0.0005!•!Run #2: 0.0003!
Min Variance: 0.0018! Max Variance: 0.0026!
Note: Testing procedures and results provided by Parmatech, an ATW Company
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420 Stainless Steel – Testing Results!
Part Designed by!Parmatech Corporation Recipient of the!
2009 Powder Metallurgy !Design Excellence Award!
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Summary!•!Great temperature uniformity is necessary
throughout the cycle!
•!Process gas management is essential for removing binder wax!
•!E"cient binder system reduces maintenance!
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Summary!•! Keeping all the parameters uniform
throughout the process can result in great uniformity of the parts’ density, carbon content, hardness & parts tolerance!
•! A special thanks to Parmatech Corporation!
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