Steel
Steel
Steel
The GKN Sinter Metals List of Materials provides an over- Many material properties are positively affected by subse-
view of PM alloys that are commonly used for powder metal quent sizing or heat treatment. It is strongly recommended
structural components and self-lubricating bearings includ- to inquire the consequences of these processes on mechan-
ing selected material properties. Other compositions can be ical and physical properties as well as on part dimensions
supplied by GKN Sinter Metals when agreed with sales and from the supplying plant.
technology. Modifications and supplements to the material
list will be introduced without reference or notification. This
does not refer to the duty of information on the current sup- Determination of Properties
ply of parts. Additional information and references are given
in the brochure related to special processes or products. Mechanical and physical properties stated in the table’s
have been determined on the basis of Sint Test Standards
(DIN 30910 Parts 1, 3 and 4).
Remarks Referring to the Tables Further details are given in DIN 30910 Part 1, Section 6.
The chemical composition is determined according to the
The tables are divided into four main sections “Standard respective standards.
References I”, “Typical Properties (References)”, “Chemical Where these are not applicable, suitable test methods
Compositions (Standard)“ and “Standard References II”. should be agreed.
lowed nor can the tensile strength be deducted from a hard- 200
Fe-C
ness measurement.
100
Density
2
Index of Contents I
Sintered Steels 4
Surface Densified Sintered Steels 6
PM Aluminium Materials 6
Stainless Steels 8
Powder Forged Steels 10
Bearing Materials (DIN-/ISO-Standard Info) 12
Bearing Materials (US-Standard Info) 14
Sintered Soft Magnetical Materials 16
Soft Magnetic Composits (SMC) 16
MIM - Case Hardened Steels 18
MIM - Corrosion Resistant Steels 18
MIM - Heat Treatable Steels 18
MIM - Soft Magnetic Steels 20
MIM - Alloys for High Temperatur Applications 20
MIM - Tool Steels 20
Economical Aspects 22
Index of Contents II 23
Material Forming Processes 24
Production Process 26
Auxiliary Operations 27
Compacting Tool 28
Principle of PM-Tools 29
Surface Quality on PM Parts 30
Hardness Comparison Table 32
Design Guidelines 34
Technical Support 36
Markets 38
GKN - Innovation by Research and Development 40
Quality - QS-Management 42
Notes 43
3
Sintered Steels
4
Chemical Compositions (Standard)1) Standard References II
DIN
C Cu Ni Mo Cr Si P Fe Others ISO MPIF
30910
[wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] 5755 35
Sint-
0.45 - 0.65 2.0 - 4.0 - - - - 0.45 - 0.65 bal. <2 n/a n/a n/a
0.45 - 0.65 2.0 - 4.0 - - - - 0.45 - 0.65 bal. <2 n/a n/a n/a
<0.3 - - - - - - bal. <2 C 00 -F-00-100 F-0000-15
0.3 - 0.7 <1 - - - - - bal. <2 C 01 -F-05-140 F-0005-20
<0.3 1.5 - 2.5 - - - - - bal. <2 C 10 -F-00C2-140 FC-0200-21
<0.3 - - - - - - bal. <2 D 00 -F-00-120 F-0000-20
0.1 - 0.5 - - - - - - bal. <2 D 00 -F-00-120 F-0000-20
0.3 - 0.7 <1 - - - - - bal. <2 D 01 -F-05-170 F-0005-25
0.5 - 0.9 - - - - - - bal. <2 n/a -F-08-240 F-0008-35
<0.3 1.5 - 2.5 - - - - - bal. <2 D 10 -F-00C2-175 FC-0200-24
0.3 - 0.7 1.5 - 2.5 - - - - - bal. <2 D 11 -F-05C2-300 FC-0205-45
0.3 - 0.7 1.5 - 2.5 - - - - - bal. <2 D 11 -F-05C2-620H FC-0205-90HT
0.5 - 0.9 1.5 - 2.5 - - - - - bal. <2 D 11 -F-08C2-390 FC-0208-60 I
0.3 - 0.6 0.0 - 2.5 1.0 - 3.0 - - - - bal. <2 n/a -F-05N2-180 FN-0205
0.3 - 0.6 0.0 - 2.5 1.0 - 3.0 - - - - bal. <2 n/a -F-05N2-800H n/a
0.6 - 0.9 0.0 - 2.5 1.0 - 3.0 - - - - bal. <2 n/a -F-08N2--260 FN-0208
0.6 - 0.9 0.0 - 2.5 1.0 - 3.0 - - - - bal. <2 n/a -F-08N2-900H n/a
0.1 - 0.5 1.0 - 2.0 1.5 - 2.0 0.3 - 0.7 - - - bal. <2 D 30 n/a n/a
0.1 - 0.5 1.0 - 2.0 1.5 - 2.0 0.3 - 0.7 - - - bal. <2 E 30 n/a n/a
0.3 - 0.7 1.0 - 2.0 1.5 - 2.0 0.3 - 0.7 - - - bal. <2 D 39 -FD-05N2C-400 FD-0205-55
0.3 - 0.7 1.0 - 2.0 1.5 - 2.0 0.3 - 0.7 - - - bal. <2 D 39 -FD-05N2C-950H FD-0205-120HT
0.3 - 0.7 1.0 - 2.0 1.5 - 2.0 0.3 - 0.7 - - - bal. <2 E 39 -FD-05N2C-440 FD-0205-65
0.5 - 0.9 1.0 - 2.0 1.5 - 2.0 0.3 - 0.7 - - - bal. <2 D 39 n/a FD-0208-60
0.1 - 0.5 1.0 - 2.0 3.5 - 4.5 0.3 - 0.7 - - - bal. <2 D 30 n/a n/a
0.1 - 0.5 1.0 - 2.0 3.5 - 4.5 0.3 - 0.7 - - - bal. <2 E 30 n/a n/a
0.3 - 0.7 1.0 - 2.0 3.5 - 4.5 0.3 - 0.7 - - - bal. <2 D 39 -FD-05N4C-420 FD-0405-60
0.3 - 0.7 1.0 - 2.0 3.5 - 4.5 0.3 - 0.7 - - - bal. <2 D 39 -FD-05N4C-930H FD-0405-130HT
0.3 - 0.7 1.0 - 2.0 3.5 - 4.5 0.3 - 0.7 - - - bal. <2 E 39 -FD-05N4C-450 FD-0405-65
0.5 - 0.9 1.0 - 2.0 3.5 - 4.5 0.3 - 0.7 - - - bal. <2 D 39 n/a FD-0408-60
0.1 - 0.5 1.5 - 2.5 3.5 - 4.5 1.3 - 1.7 - - - bal. <2 D 31 n/a n/a
0.1 - 0.5 1.5 - 2.5 3.5 - 4.5 1.3 - 1.7 - - - bal. <2 E 31 n/a n/a
0.4 - 0.8 1.5 - 2.5 3.5 - 4.5 1.3 - 1.7 - - - bal. <2 D 32 n/a FLDN4C2-4908
0.4 - 0.8 1.5 - 2.5 3.5 - 4.5 1.3 - 1.7 - - - bal. <2 E 32 n/a FLDN4C2-4908
0.1 - 0.5 1.5 - 2.5 - 1.3 - 1.7 - - - bal. <2 D 31 n/a n/a
0.1 - 0.5 1.5 - 2.5 - 1.3 - 1.7 - - - bal. <2 E 31 n/a n/a
0.4 - 0.8 1.5 - 2.5 - 1.3 - 1.7 - - - bal. <2 D 32 n/a FLDC2-4908
0.4 - 0.8 1.5 - 2.5 - 1.3 - 1.7 - - - bal. <2 E 32 n/a FLDC2-4908
<0.3 - - - - - 0.3 - 0.6 bal. <2 D 35 -F-00P05-210 FY-4500-20W
0.4 - 0.7 - 1.0 - 3.0 0.65 - 0.95 - - - bal. <2 n/a n/a FLN2-4405
0.4 - 0.7 - 1.0 - 3.0 0.65 - 0.95 - - - bal. <2 n/a n/a n/a
0.4 - 0.7 - 0.35 - 0.55 0.50 - 0.85 - - - bal. <2 n/a n/a FL-4205
0.4 - 0.7 - 0.35 - 0.55 0.50 - 0.85 - - - bal. <2 n/a n/a n/a
0.6 - 0.9 1.0 - 3.0 1.0 - 3.0 0.65 - 0.95 - - - bal. <2 n/a n/a FLNC-4408
0.6 - 0.9 1.0 - 3.0 1.6 - 2.0 0.43 - 0.60 - - - bal. <2 n/a n/a FLC-4608
0.6 - 0.9 0.5 - 2.0 2.4 - 3.2 0.43 - 0.60 - - - bal. <2 n/a n/a n/a
< 0.3 - - - - - 0.45 - 0.65 bal. <2 D 35 n/a n/a
0.4 - 0.8 - 0.5 - 2.5 0.6 - 1.1 0.8 - 1.2 0.4 - 0.8 - bal. <2 n/a n/a n/a
0.2 - 0.8 - 0.5 - 2.5 0.6 - 1.1 0.8 - 1.2 0.4 - 0.8 - bal. <2 n/a n/a n/a
UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield Strength
A, El: Fracture Elongation E: Youngs Modulus
5
Surface Densified Sintered Steels
GKN Core Surface Typical core UTS YS 0,2 A2) Surface Core E
Typical
SM Material density density3) density El2) hardness4) hardness
composition1)
Code [g/cm3] [g/cm3] [g/cm3] [MPa] [MPa] [%] HV0,1 HB [GPa]
PMET 1002D/F 6.8 - 7.2 > 7.6 Fe-0,2C 7.00 230 150 5 180 75 140
PMET 1005D/F 6.8 - 7.2 > 7.6 Fe-0,5C 7.00 300 180 3 250 90 140
PMET 1025D/F 6.8 - 7.2 > 7.6 Fe2Cu-0,5C 7.00 500 330 2,5 300 140 140
PMET 1025E/F > 7.2 > 7.6 Fe2Cu-0,5C 7.25 570 360 3 300 180 160
PMET 4402D/F 6.8 - 7.2 > 7.6 Fe0,85Mo-0,2C 7.00 280 180 4 260 120 140
PMET 4402E/F > 7.2 > 7.6 Fe0,85Mo-0,2C 7.25 340 220 5 260 130 160
1)
In addition to the elements mentioned, further alloying elements up to 2 % are admitted.
2)
Case hardening or carbo-nitriding is perfomed depending on the required case depth and is in general followed by a stress relief operation as well.
3)
The surface density can be exactly determined by metallographic investigations combined with quantitative image analysis.
4)
The indicated surface hardness is determined after the surface densification but prior to a potential heat treatment. The increased hardness at the
surface can be explained by work hardening due to the deformation of the material during the densification step.
PM Aluminium Materials 4)
PMET Al14Si-T6 2.55 - 2.65 Al2.5Cu0.5Mg14Si 2.62 320 300 80 <1 115 79
PMET Al7075 2.74 - 2.78 Al5.5Zn1.6Cu2.5Mg 2.76 315 270 80 1.2 100 65
PMET Al7075-T6 2.74 - 2.78 Al5.5Zn1.6Cu2.5Mg 2.76 420 410 120 1 135 65
1)
In addition to the elements mentioned, further alloying elements up to 2 % are admitted.
2)
Other MMC materials are currently under development
3)
FEL - Based on 10,000,000 cycles of completely reversed stress (R = -1) using an R. R. Moore type of instrument. Specimens prepared and polished in
accordance with ASTM standard E111-04
4)
Being evaluated
5)
Sizing will reduce the elongation
6
Chemical Compositions (Standard)1) Standard References II
C Cu Ni Mo Cr Si P Mn Fe Others
DIN
ISO MPIF
Remark 30910
5755 35
[wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] Sint-
case hardening steel2) 0.1 - 0.5 - - 0.6 - 1.1 - - - - bal. <2 n/a n/a n/a
case hardening steel2) 0.1 - 0.5 - - 0.6 - 1.1 - - - - bal. <2 n/a n/a n/a
UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield Strength
A, El: Fracture Elongation E: Youngs Modulus
I
DIN
Al Cu Zn Si Mg Others ISO ASTM
Remark 30903 MPIF
[wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] 5755 B595-95
Sint-
bal. 4.0 - 5.0 - 0.7 0,5 <0.5 D73/E73 n/a n/a ACT1-2014 type II
T6 heat treated bal. 4.0 - 5.0 - 0.7 0,5 <0.5 F73 n/a n/a ACT6-2014 type II
T6 heat treated bal. 0.2 - 0.5 1 <0.5 E73 n/a n/a AT6-6061 type II
T6 heat treated bal. 2.0 - 3.0 - 13 - 15 0.5 <0.5 n/a n/a n/a n/a
bal. 1.6 5.0 - 6.0 - 2.5 <1 n/a n/a n/a n/a
T6 heat treated bal. 1.6 5.0 - 6.0 - 2.5 <1 n/a n/a n/a n/a
Thermal Con-
ductivity:
bal. - - - X <15 n/a n/a n/a n/a
230 - 240 W/
(m·K)
UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield Strength
A, El: Fracture Elongation E: Youngs Modulus
7
Stainless Steels 4)
PMET SS303C-N1 6.4 - 6.8 Fe18Cr9Ni 6.40 270 220 90 <1 - 62 105 Nitrogen cont. sint. atmosphere
PMET SS303C-N2 6.4 - 6.8 Fe18Cr9Ni 6.50 380 290 110 5 - 63 115 Nitrogen cont. sint. atmosphere
PMET SS303D-N2 6.8 - 7.2 Fe18Cr9Ni 6.90 470 310 145 10 - 70 140 Nitrogen cont. sint. atmosphere
PMET SS303C-H 6.4 - 6.8 Fe18Cr9Ni 6.60 270 120 105 17 - 21 115 Hydrogen atmosphere
PMET SS303D-H 6.8 - 7.2 Fe18Cr9Ni 6.90 330 170 130 20 - 35 140 Hydrogen atmosphere
PMET SS304C-N 6.4 - 6.8 Fe18Cr10Ni 6.60 370 280 105 5 125 - 115 Nitrogen cont. sint. atmosphere
PMET SS304C-N1 6.4 - 6.8 Fe19Cr10Ni 6.40 300 260 105 <1 - 61 105 Nitrogen cont. sint. atmosphere
PMET SS304C-N2 6.4 - 6.8 Fe19Cr10Ni 6.50 390 280 125 10 - 62 115 Nitrogen cont. sint. atmosphere
PMET SS304D-N2 6.8 - 7.2 Fe19Cr10Ni 6.90 480 310 160 13 - 68 140 Nitrogen cont. sint. atmosphere
PMET SS304C-HL 6.4 - 6.8 Fe19Cr10Ni 6.60 280 170 110 10 - 35 115 Hydrogen atmosphere
PMET SS304C-H 6.4 - 6.8 Fe19Cr10Ni 6.60 300 120 115 23 - 30 115 Hydrogen atmosphere
PMET SS304D-H 6.8 - 7.2 Fe19Cr10Ni 6.90 390 180 145 26 - 45 140 Hydrogen atmosphere
PMET SS304E-N > 7.2 Fe18Cr10Ni 7.25 520 420 140 2.5 130 - 160 sintered with shrinkage at HT
PMET SS316C-N 6.4 - 6.8 Fe16Cr12Ni2,5Mo 6.60 410 270 120 2 115 - 115 Nitrogen cont. sint. atmosphere
PMET SS316C-N1 6.4 - 6.8 Fe17Cr12Ni2.5Mo 6.4 280 230 75 <1 - 59 105 Nitrogen cont. sint. atmosphere
PMET SS316C-N2 6.4 - 6.8 Fe17Cr12Ni2.5Mo 6.5 410 270 95 10 - 62 115 Nitrogen cont. sint. atmosphere
PMET SS316C-HL 6.4 - 6.8 Fe17Cr12Ni2.5Mo 6.6 240 170 105 7 - 33 115 Hydrogen atmosphere
PMET SS316C-H 6.4 - 6.8 Fe17Cr12Ni2.5Mo 6.6 280 140 90 18 - 20 115 Hydrogen atmosphere
PMET SS316D-N 6.8 - 7.2 Fe16Cr12Ni2,5Mo 6.90 480 310 130 3 130 - 135 Nitrogen cont. sint. atmosphere
PMET SS316D-H 6.8 - 7.2 Fe16Cr12Ni2,5Mo 6.90 280 200 90 8 80 - 135 Hydrogen atmosphere
PMET SS409CbE-H > 7.2 Fe12Cr0,5Nb 7.25 380 200 130 12 100 - 160 sintered with shrinkage at HT
PMET SS409D-H 6.8 - 7.2 Fe11Cr0.5Cb 7.0 320 180 - 14 - 45 165 Hydrogen atmosphere
PMET SS410C 6.4 - 6.8 Fe12Cr-0.2C 6.5 720 710 240 <1 - 23 HRC 125 Tempered at 180°C
Nitrogen containing sintering
PMET SS410C-N 6.4 - 6.8 Fe12Cr 6.60 420 320 120 <1 220 - 115
atmosphere
PMET SS410D-H 6.8 - 7.2 Fe12Cr 6.9 330 180 125 16 - 45 165 Hydrogen atmosphere
PMET SS430C-N 6.4 - 6.8 Fe16Cr 6.60 450 330 125 1 240 - 115 Nitrogen cont. sint. atmosphere
PMET SS430C-H 6.4 - 6.8 Fe16Cr 6.60 270 190 90 6 90 - 115 Hydrogen atmosphere
PMET SS430D-N2 6.8 - 7.2 Fe16Cr 7.1 410 240 170 5 - 70 170 Nitrogen cont. sint. atmosphere
PMET SS430D-H 6.8 - 7.2 Fe16Cr 7.1 340 210 170 20 - 45 170 Hydrogen atmosphere
PMET SS434D-N2 6.8 - 7.2 Fe16Cr1Mo 7.0 410 240 150 8 - 65 165 Nitrogen cont. sint. atmosphere
PMET SS434D-H 6.8 - 7.2 Fe16Cr1Mo 7.0 340 210 150 15 - 50 165 Hydrogen atmosphere
PMET SS434C-N 6.4 - 6.8 Fe16Cr1Mo 6.60 460 340 130 1 250 - 115 Nitrogen cont. sint. atmosphere
1)
In addition to the elements mentioned, further alloying elements up to 2 % are admitted.
2)
Sizing will reduce the elongation.
3)
Bending load. 2 x 106 cycles, notch factor αk = 1.0 (ref. 30912 Part 6); R = -1.
4)
Corrosion resistance depending on sintering temperature and medium.
8
Chemical Compositions (Standard)1) Standard References II
DIN
C Ni Mo Cr Si P Mn Fe Others ISO MPIF
30910
[wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] 5755 35
Sint-
< 0.15 8.0 - 13.0 - 17.0 - 19.0 <1 < 0.20 < 2.0 bal. <2 n/a -FL303-170N SS-303N1-25
< 0.15 8.0 - 13.0 - 17.0 - 19.0 <1 < 0.20 < 2.0 bal. <2 n/a n/a SS-303N2-35
< 0.15 8.0 - 13.0 - 17.0 - 19.0 <1 < 0.20 < 2.0 bal. <2 n/a -FL303-260N SS-303N2-38
< 0.03 8.0 - 13.0 - 17.0 - 19.0 <1 < 0.20 < 2.0 bal. <2 n/a n/a SS-303L-12
< 0.03 8.0 - 13.0 - 17.0 - 19.0 <1 < 0.20 < 2.0 bal. <2 n/a n/a SS-303L-15
<0.1 8.0 - 12.0 - 18.0 - 20.0 <1 <0.04 <2 bal. <2 n/a -FL304-210N SS 304N2-33
< 0.08 8.0 - 12.0 - 18.0 - 20.0 <1 < 0.04 < 2.0 bal. <2 n/a -FL304-210N SS-304N1-30
< 0.08 8.0 - 12.0 - 18.0 - 20.0 <1 < 0.04 < 2.0 bal. <2 n/a n/a SS-304N2-33 I
< 0.08 8.0 - 12.0 - 18.0 - 20.0 <1 < 0.04 < 2.0 bal. <2 n/a -FL304-260N SS-304N2-38
< 0.03 8.0 - 12.0 - 18.0 - 20.0 <1 < 0.04 < 2.0 bal. <2 n/a n/a SS-304H-20
< 0.03 8.0 - 12.0 - 18.0 - 20.0 <1 < 0.04 < 2.0 bal. <2 n/a n/a SS-304L-13
< 0.03 8.0 - 12.0 - 18.0 - 20.0 <1 < 0.04 < 2.0 bal. <2 n/a n/a SS-304L-18
<0.1 8.0 - 12.0 - 18.0 - 20.0 <1 <0.04 <2 bal. <2 n/a -FL304-210N SS 304N2-33
<0.1 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 <1 <0.04 <2 bal. <2 C 40 -FL316-170N SS 316N2-33
< 0.08 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 < 1.0 < 0.04 < 2.0 bal. <2 C 40 -FL316-170N SS-316N1-25
< 0.08 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 < 1.0 < 0.04 < 2.0 bal. <2 C 40 n/a SS-316N2-33
< 0.03 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 < 1.0 < 0.04 < 2.0 bal. <2 C 40 n/a SS-316H-20
< 0.03 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 < 1.0 < 0.04 < 2.0 bal. <2 C 40 n/a SS-316L-15
<0.1 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 <1 <0.04 <2 bal. <2 D 40 -FL316-260N SS 316N2-38
<0.1 10.0 - 14.0 2.0 - 3.0 16.0 - 18.0 <1 <0.04 <2 bal. <2 D 40 -FL316-150 SS 316L-22
Nb / Cb
<0.1 0 - 0.5 - 11.5 - 13.5 <1 <0.04 <1 bal. n/a n/a SS 409LE
0.3 - 1
< 0.03 - - 10.50 - 11.75 < 1.0 < 0.04 <1 bal. <2 n/a n/a SS-409L
< 0.25 - - 11.50 - 13.50 < 1.0 < 0.04 <1 bal. <2 n/a -FL410-620H SS-410-90HT
<0.1 - - 11.5 - 13.5 <1 <0.04 <1 bal. <2 C 43 -FL410-140 SS 410
< 0.03 - - 11.50 - 13.50 < 1.0 < 0.04 <1 bal. <2 C 43 -FL410-140 SS-410L-20
<0.1 - - 16.0 - 18.0 <1 <0.04 <1 bal. <2 C 42 -FL430-170 SS 430
<0.1 - - 16.0 - 18.0 <1 <0.04 <1 bal. <2 C 42 -FL430-170 SS 430L
< 0.08 - - 16.00 - 18.00 < 1.0 < 0.04 <1 bal. <2 n/a n/a SS-430N2-28
< 0.03 - - 16.00 - 18.00 < 1.0 < 0.04 <1 bal. <2 n/a -FL430-170 SS-430L-24
< 0.08 - 0.75 - 1.25 16.00 - 18.00 < 1.0 < 0.04 <1 bal. <2 n/a n/a SS-434N2-28
< 0.03 - 0.75 - 1.25 16.00 - 18.00 < 1.0 < 0.04 <1 bal. <2 n/a -FL434-170 SS-434L-24
<0.1 - 0.75 - 1.25 16.0 - 18.0 <1 <0.04 <1 bal. <2 n/a -FL434-170 SS 434
UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield Strength
A, El: Fracture Elongation E: Youngs Modulus
9
Powder Forged Steels
Standard
Typical Properties (References)
References I
PMET 1022F-H2 >7.6 Fe2Cu-0,2C 7.65 380 250 150 24 125 200 case hardening steel4) < 0.3 1.5 - 2.5
PMET 1026F >7.6 Fe2Cu-0,6C 7.65 810 530 270 12 250 200 0.4 - 0.8 1.5 - 2.5
PMET 1026FA >7.81. Fe2Cu-0.6C 7.83 950 610 4406) 8 27 HRC 210 5)
1.8 - 2.2
PMET 4202F-H2 >7.6 Fe0,45Ni0,6Mo0,25Mn-0,2C 7.65 520 380 180 20 150 200 case hardening steel4) < 0.3 -
PMET 4206F >7.6 Fe0,45Ni0,6Mo0,25Mn-0,6C 7.65 760 520 250 12 230 200 0.4 - 0.8 -
PMET 4206F-H1 >7.6 Fe0,45Ni0,6Mo0,25Mn-0,6C 7.65 1310 1170 420 5 38 HRC 200 quench + temper 0.4 - 0.8 -
PMET 4602F-H2 >7.6 Fe1.8Ni0.55Mo-0.2C 7.65 550 410 200 20 180 200 case hardening steel4) < 0.3 -
1)
In addition to the elements mentioned, further alloying elements up to 2 % are admitted.
2)
Sizing will reduce the elongation.
3)
Bending load. 2 x 106 cycles, notch factor αk = 1.0 (ref. 30912 Part 6); R = -1.
4)
Case hardening or carbo-nitriding is perfomed depending on the required case depth and is in general followed by a stress relief operation as well.
5)
Carbon content shall be as specified by the purchaser. Unless agreed upon between the purchaser and manufacturer, the forged product carbon content shall
be within +/- 0.1% of the specified carbon content.
6)
For FEL, polished specimen and R = 0.1. Runout 1 x 107 cycles. Other fatigue information available on request.
7)
Details on request.
10
Chemical Compositions (Standard)1) Standard References II
DIN
Ni Mo Cr Si P Mn Fe Others ISO MPIF ASTM
30910
[wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] [wt.-%] 5755 35 B 848
Sint-
< 0.1 < 0.05 < 0.1 < 0.03 < 0.03 0.30 - 0.60 bal. <2 n/a n/a P/F-11C60 P/F-11C60 Grade A
< 0.1 < 0.05 < 0.1 < 0.03 < 0.03 0.30 - 0.60 bal. <2 n/a n/a n/a n/a
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4220 P/F-4220 Grade A
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4220 P/F-4220 Grade A
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4220 P/F-4220 Grade A
I
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4240 P/F-4240 Grade A
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4240 P/F-4240 Grade A
0.3 - 0.6 0.3 - 0.7 - - - 0.1 - 0.4 bal. <2 n/a n/a P/F-4220 n/a
0.3 - 0.6 0.3 - 0.7 - - - 0.1 - 0.4 bal. <2 n/a n/a P/F-4260 n/a
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4260 P/F-4260 Grade A
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4260 P/F-4260 Grade A
0.40 - 0.50 0.55 - 0.65 < 0.1 < 0.03 < 0.03 0.25 - 0.35 bal. <2 n/a n/a P/F-4260 P/F-4260 Grade A
0.3 - 0.6 0.3 - 0.7 - - - 0.1 - 0.4 bal. <2 n/a n/a P/F-4260 n/a
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4620 P/F-4620 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4620 P/F-4620 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4620 P/F-4620 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4640 P/F-4640 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4640 P/F-4640 Grade A
1.4 - 2.2 0.3 - 0.7 - - - 0.1 - 0.4 bal. <2 F 30 n/a P/F-4620 n/a
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4660 P/F-4660 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4660 P/F-4660 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4660 P/F-4660 Grade A
1.75 - 2.00 0.50 - 0.60 < 0.1 < 0.03 < 0.03 0.10 - 0.25 bal. <2 n/a n/a P/F-4660 P/F-4660 Grade A
UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield Strength
A, El: Fracture Elongation E: Youngs Modulus
11
Bearing Materials (DIN-/ISO-Standard Info)
PMET B-FMD4) 6.0 - 6.4 Fe36Cu4Sn1C 6.2 22 120 50 Fe-base 0.8 - 1.2
PMET B-M36MD4) 6.0 - 6.4 Fe3Cu1,5C 6.2 18 170 60 Fe-base 1.0 - 2.0
PMET B-M21MD4) 6.0 - 6.4 Fe2Cu0,4C 6.2 20 270 70 Fe-base 0.2 - 0.6
PMET B-MP208LD4) 5.6 - 6.0 Fe20Cu1,8C 5.8 25 120 40 Fe-base 1.2 - 2.4
PMET B-MP208MD4) 6.0 - 6.4 Fe20Cu1,8C 6.2 20 140 50 Fe-base 1.2 - 2.4
PMET B-H4LD4) 6.2 - 6.6 Cu9Sn1,5C 6.4 24 120 30 Bronze 1.0 - 2.0
PMET B-H4MD4) 6.6 - 7.0 Cu9Sn1,5C 6.8 19 160 35 Bronze 1.0 - 2.0
1)
In addition to the elements mentioned, further alloying elements up to 2 % are admitted.
2)
The oil content is at least 90 % of the open porosity.
3)
Values determined after sizing.
4)
Carbon mainly in the form of free graphite.
12
Chemical Compositions (Standard)1) Standard References II
13
Bearing Materials (US-Standard Info)
PMET B-B0000 6.0 - 6.4 Cu10Sn 6.2 130 24 Low graphite bronze
PMET B-B0000-A 6.4 - 6.8 Cu10Sn 6.6 180 19 Low graphite bronze
PMET B-B0000-B 6.8 - 7.2 Cu10Sn 7.0 260 12 Low graphite bronze
PMET B-B00012 6.0 - 6.4 Cu10Sn1C 6.2 120 22 Medium graphite bronze
PMET B-B00012-A 6.4 - 6.8 Cu10Sn1C 6.6 160 17 Medium graphite bronze
PMET B-B00012-A 6.8 - 7.2 Cu10Sn1C 7.0 210 17 Medium graphite bronze
PMET B-B00025-B 6.2 - 6.6 Cu10Sn3C 6.4 100 5 High graphite bronze
1)
In addition to the elements mentioned, further alloying elements up to 2 % are admitted.
14
Chemical Compositions (Standard)1) Standard References II
2.5 - 5.0 82.8 - 88.3 9.5 - 10.5 - - <2 n/a n/a CTG-1004-K10
I
2.5 - 5.0 82.8 - 88.3 9.5 - 10.5 - - <2 n/a n/a CTG-1004-K15
0.5 - 1.3 34.0 - 38.0 3.5 - 4.5 54.2 - 62.0 - <2 n/a -F-03C36T-K90 FCTG-3604-K16
0.5 - 1.3 34.0 - 38.0 3.5 - 4.5 54.2 - 62.0 - <2 n/a -F-03C36T-K120 FCTG-3604-K22
0.5 - 1.3 50.2 - 58.0 5.5 - 6.5 50.2 - 58.0 - <2 n/a -F-03C45T-K70 CFTG-3806-K14
0.5 - 1.3 50.2 - 58.0 5.5 - 6.5 50.2 - 58.0 - <2 n/a -F-03C45T-K100 CFTG-3806-K22
0.0 - 0.3 9.0 - 11.0 - 86.7 - 91.0 - <2 n/a n/a FC-1000-K20
0.0 - 0.3 9.0 - 11.0 - 86.7 - 91.0 - <2 n/a n/a FC-1000-K30
0.3 - 0.6 1.5 - 3.9 - 93.5 - 98.2 - <2 n/a n/a FC-0205-K20
0.6 - 0.9 1.5 - 3.9 - 93.2 - 97.9 - <2 n/a n/a FC-0208-K25
0.6 - 0.9 4.0 - 6.0 - 91.1 - 95.4 - <2 n/a n/a FC-0508-K35
15
Sintered Soft Magnetic Materials
Bmax
GKN Typical Coercivity A
@ 1200 Perme- Hard- Hard- UTS YS0,2 E Compo-
SM Material Density Hc El
A/m ability ness ness [MPa] [MPa] [GPa] sition
Code [g/cm³] [A/m] [%]
[T]
PM4EM 1000D 7.0 145 1.05 2,300 50 HRF 50 HB 195 115 12 140 Fe
PM4EM 1000E 7.25 145 1.20 2,900 55 HRF 55 HB 255 155 17 155 Fe
PM4EM 10P40D 7.15 120 1.25 3,200 55 HRB 95 HB 380 270 12 155 Fe0.45P
PM4EM 10P40E 7.4 120 1.35 3,600 65 HRB 115 HB 415 280 15 170 Fe0.45P
PM4EM 10S30D 7.2 80 1.30 5,000 75 HRB 135 HB 380 275 15 155 Fe3Si
PM4EM 50NiE 7.5 25 1.20 10,000 40 HRB 80 HB 275 170 15 110 Fe50Ni
PM4EM SS410C 6.7 390 1.15 340 85 HRB 165 HB 280 150 10 125 Fe12Cr
PM4EM SS410D 7.0 330 1.23 410 95 HRB 210 HB 320 190 14 140 Fe12Cr
PM4EM SS430C 6.7 320 1.06 320 70 HRB 120 HB 300 170 12 125 Fe16Cr
PM4EM SS430D 7.0 280 1.17 370 90 HRB 185 HB 340 200 16 140 Fe16Cr
1)
Properties can be influenced and optimized by the proper selection of processing conditions.
Consult an GKN Sinter Metals expert on the specifics of the application for the best solution.
2)
C <0.1 wt-%; Co < 0.1 wt-%
Typical Properties*
16
Chemical Composition2) Standard References II
DIN Applications
Fe P Ni Si Cr Other DIN EN
30910 MPIF
[wt-%] [wt-%] [wt-%] [wt-%] [wt-%] [wt-%] 10331
Sint-
Transverse
Rupture Applications
Density
P @ 2000Hz Strength
[g/cm³]
[W/kg] TRS
[MPa]
384 39 up to 7.4
377 42 up to 7.5
329 62 up to 7.3
17
MIM - Case Hardened Steels
Material A
Density Rm Rp 0.2 A Hardn. Rm Rp 0.2 Hardn. C Ni Cr Mo Mn
El
[g/cm³] [MPa] [MPa] [%] [HV 10] [MPa] [MPa] [HV 10] [%] [%] [%] [%] [%]
[%]
1.90-
IMET Ni 2 > 7,40 280 140 25 90 by agreement < 0.1 - - -
2.20
7.50-
IMET Ni 8 > 7,40 350 200 15 90 by agreement < 0.1 - - -
8.50
0.12- 0.40- 0.40- 0.15-
IMET 8620 > 7,40 400 220 15 90 by agreement -
0.23 0.70 0.60 0.25
Material A
Density Rm Rp 0.2 A Hardn. Rm Rp 0.2 Hardn. C Ni Cr Mo Mn Si
EL
[g/cm³] [MPa] [MPa] [%] [HV 10] [MPa] [MPa] [HV 10] [%] [%] [%] [%] [%] [%]
[%]
15.50-
IMET 430 > 7.40 350 200 20 190 n/a <0.08 - - <1 <1
17.50
3.00- 15.00-
IMET 17-4 PH > 7.50 800 700 3 250 1000 950 2 350 <0.07 - <1 <1
5.00 17.50
Material Hard- A
Density Rm Rp 0.2 A Rm Rp 0.2 Hardness C Ni Cr Mo Mn Si
ness EL
[g/cm³] [MPa] [MPa] [%] [MPa] [MPa] [HV 10] [%] [%] [%] [%] [%] [%]
[HV 10] [%]
0.40- 1.90-
IMET Ni 2C > 7.40 450 250 5 170 1000 800 2 600 - - - -
0.70 2.20
0.40- 7.50-
IMET Ni 8C > 7.40 700 350 3 320 1200 1000 2 600 - - - -
0.70 8.50
0.35- 0.90- 0.15-
IMET Cr Mo 4 > 7.40 600 350 4 110 1350 1150 2 450 - - -
0.45 1.20 0.30
0.45- 0.50- 0.40- 0.25- 0.30-
IMET 8740 > 7.40 600 350 5 180 1600 1100 1 450 -
0.55 0.80 0.60 0.40 0.55
1)
Percent by weight
18
Other Designation
Properties Applications
Si Cu Fe Mat no: AISI/SAE/
Others
[%] [%] [%] DIN MPIF
I
Other Designation
Properties Applications
Cu Nb Fe Mat no:
AISI/SAE Others
[%] [%] [%] DIN
Other Designation
Properties Applications
Fe Mat no:
AISI/SAE Others
[%] DIN
carbonyl iron
bal. n/a n/a
with 2% nickel miscellaneous applications (e. g. mechanical engi-
excellent surface finish, high strength
carbonyl iron neering, firearm components)
bal. n/a n/a
with 8% nickel
AISI/SAE mechanical engineering, firearms, gearbox com-
bal. 1.7225 42 CrMo 4
4140 high strength and ductility, large heat ponents
AISI/SAE treated diameter wear resistant, highly loaded components in me-
bal. 1.6546 40NiCrMo2 2
8740 chanical engineering and automotive industry
Rm: ultimate tensile strength RP0.2: yield strength A, El: elongation to fracture
19
MIM - Soft Magnetic Steels
Material Hard- A
Density Rm Rp 0.2 A Rm Rp 0.2 Hardn. C Ni Cr Mo Mn
ness El
[g/cm³] [MPa] [MPa] [%] [MPa] [MPa] [HV 10] [%] [%] [%] [%] [%]
[HV 10] [%]
IMET FN 50 > 7.40 400 150 25 110 n/a < 0.1 49.50-50.50 - - -
Material A
Density Rm Rp 0.2 A Hardn. Rm Rp 0.2 Hardn. C Ni Cr Mo Co Al
El
[g/cm³] [MPa] [MPa] [%] [HV 10] [MPa] [MPa] [HV 10] [%] [%] [%] [%] [%] [%]
[%]
IMET GHS-4 *) >7.70 700 550 1 310 n/a 2.0-2.4 38.0-42.0 11.0-13.0 5.0-7.0 - -
IMET 310N **) >7.55 650 380 7 220 n/a 0.20-0.50 19.0-22.0 24.0-26.0 - - -
IMET N 90 ***) > 7.8 1000 620 10 280 1100 650 10 300 ≤ 0.13 bal. 18.0-21.0 - 15.0-21.0 1.0-2.0
*)
Heat and wear resistant alloy
**)
Heat resistant alloy
***)
Superalloy
Material A
Density Rm Rp 0.2 A Hardn. Rm Rp 0.2 Hardness C Cr W
El
[g/cm³] [MPa] [MPa] [%] [HV 10] [MPa] [MPa] [HV 10] [%] [%] [%]
[%]
IMET M2 > 7.70 1100 700 1 480 - - - 800 0.95-1.05 3.80-4.50 5.50-6.75
1)
Percent by weight
20
position1) Other Designation
Properties Applications
Si Cu Fe Mat no:
AISI/SAE/MPIF Others
[%] [%] [%] DIN
Properties Applications
Ti Si Mn V Nb Fe Mat no:
AISI/SAE Others
[%] [%] [%] [%] [%] [%] DIN
Properties Applications
Mo V Fe Mat no:
AISI/SAE Others
[%] [%] [%] DIN
Rm: ultimate tensile strength RP0.2: yield strength A, El: elongation to fracture
21
Economical and Ecological Aspects
The PM production technique excels when compared with The parameters of the manufacturing process are deter-
the cost of other different metal shaping processes. Three mined by the functional requirements of the component
important criteria characterize the process: properties, related to the chemical composition, density
and precision of the component. Cost comparison with
competing technologies, such as stamping, cold extrusion,
• 100 % material utilization (no scrap loss) precision casting, precision forging and plastic moulding is
• wide variety of designs possible with limited strongly influenced by requirements of material, shape and
impact on production costs, and according production quantity.
to customer application needs
• wide range of adaptability of material properties to The higher the requirements on material properties, the
the function of the components closer the tolerances required, and larger the production
• environmental friendly quantity the greater the advantage is for using a sintered
component. Even when machining is necessary due to close
tolerances or to geometry, the overall economics of a sin-
In spite of the fact that metal powder is more expensive tered blank often turn out to be favourable.
than conventional steel, this difference is offset by the ad-
vantage of nearly 100 % material utilization. This holds for Although the PM shaping process is flexible as to quanti-
the typical PM part of less than 1 kg in weight and also for ties, initial investment in tooling requires larger production
heavier parts, whereas the initial weight of the conventional runs.
steel blank is much greater than that of the machined part.
A further significant advantage - the PM process saves nat-
The large amount of design capability leads to parts that ural resources through recycling, conserves raw materials
may combine several functions in one component, often and the manufacturing process yields low emissions.
replacing multiple piece assemblies made by blanking or
machining. For example, inner and outer gears, through and
blind holes of varied profiles, and countersunk or stepped
openings may be produced in a single shaping operation.
TM
The efficiency depends on the operating speed of the press,
the flow properties of the powder and the height of the com-
ponents to be compacted. The sintering costs are influenced
by the required material quality, sintering temperature and
time, protective atmosphere, but are fairly independent
from parts geometry.
22
Index of Contents II
Sintered Steels 4
Surface Densified Sintered Steels 6
PM Aluminium Materials 6
Stainless Steels 8
Powder Forged Steels 10
Bearing Materials (DIN-/ISO-Standard Info) 12
Bearing Materials (US-Standard Info) 14
Sintered Soft Magnetical Materials 16
Soft Magnetic Composits (SMC) 16
MIM - Case Hardened Steels 18
MIM - Corrosion Resistant Steels 18
MIM - Heat Treatable Steels 18
MIM - Soft Magnetic Steels 20
MIM - Alloys for High Temperatur Applications 20
MIM - Tool Steels 20
Economical Aspects 22
Index of Contents II 23
Material Forming Processes 24
Production Process 26
Auxiliary Operations 27
Compacting Tool 28
Principle of PM-Tools 29
Surface Quality on PM Parts 30
Hardness Comparison Table 32
Design Guidelines 34
Technical Support 36
Markets 38
GKN - Innovation by Research and Development 40
Quality - QS-Management 42
Notes 43
23
Material Forming Processes
General Remarks
The sinter metal process covers a wide range of manufactured parts; from highly porous materials for filter applications, to full or
near full dense components such as sinter forged engine and gear box parts.
Conventional PM
The majority of PM products are manufactured using the “Conventional” method pio-
neered in the 1930’s. Improvements in materials and processes has resulted in a new
class of high performance, consistent, competitive and creative product.
Aluminium PM
New PM Aluminium materials developed by GKN are challenging paradigms about
material performance offering a new option to engineers when weight reduction and
performance improvement are priorities.
Powder Forging
This process step creates a nearly full dense part with high dynamic loads by utilizing
a closed die which creates high axial precision.
24
Soft Magnetic PM
Growing demand for electric motors and electro-mechanical systems has highlighted
a need for new design and material solutions. PM technology and new soft magnetic
materials enable engineers to develop smaller products with improved performance.
Surface Densified PM
A new PM technology that enables high density performance where required, without
the weight penalty of fully dense products. This is an ideal process for complex, highly
stressed gears requiring high performance and light weight.
II
Sintered Bearings
Sintered self-lubricating bearings are indispensible machine elements. When used in
typical applications, they are much more cost effective than roller bearings and even
require less space. In contrast to plastic bearings, sintered bearings exhibit a pore vol-
ume of 15 to 30 percent which serves as an oil reservoir for the entire lifetime.
25
Production Process
1. Blending / Mixing
Lubricant Graphite
Raw material in powder form is mixed according to the specified Copper
composition. Powder
Prealloyed powders may be used as well as elemental powders.
Iron
Alloying Elements Powder Powder Blends
2. Compaction
3. Sintering
4. Sizing / Forging
5. Finished Part
In most of the cases the production process ends latest after siz-
ing / forging, leaving behind the finished part. However, if the
customer requires closer tolerances or more complex shapes,
GKN is able to fulfill these with auxiliary operations.
26
Production Process - Optional Auxiliary Operations
II
Turned inner cone Turned outer diameter
27
The Compacting Tool
Core rod
Base plate
Joining plate
In the most simple case – for a tablet shape – the tool con-
sists of a die, and an upper and lower punch. Individually
controlled press movement of these tool components con-
trols the powder fill, compression stroke, and part ejection.
28
Principle of PM-Tools - Dimensional Accuracy
The process of axial compaction offers a wide variety of To avoid tooling problems a minimum wall thickness of
shaping possibilities and leads to excellent reproducibility 2 mm should be maintained. The following aspects are im-
of the dimensions. The shaping of a sintered component is portant for the ejection of the part from the die:
essentially defined by the tool design and its manufacture.
The appropriate lay-out of the component’s geometry and • Ejection draft angles on profile of the outer surface
selection of the suitable material according to the PM pro- are not necessary
cess has a strong influence on tool life and -consequently- • Face contours should have draft angles of less
on the price of the part. It is therefore worthwhile to consider than 7°
some of the guidelines of design related to the PM process. • Junctions and edges should have radii when formed in
The specific forming parts of a tool are a die, core rod, upper the die
and lower punch. The most important options in the design
of a compacting tool are demonstrated in figure 1. Possibilities to press threads, grooves and bores perpendic-
The die creates the outer shape of the component. It may ular to the compacting direction are very limited and most
have any geometry. Steps or slopes are possible in the axial often need to be added as secondary machining. However
direction. Bores and apertures in the direction of compact- due to a special GKN owned technology undercuts are very
ing are shaped by core rods, which also may be contoured. possible to a certain extent.
The face contours of the parts are shaped by punches. Sharp The design guidelines are shown on page 34.
chamfers or sharp junctions to the area of the outer surface
have to be avoided. Steps of max. 15 % of the final compo- Dimensional Accuracy
nent height can be produced without split punches.
Figure 1
GKN Sinter Metals endeavours during the development II
phase to find a custom tailored solution for production runs
and offers components fulfilling exactly the requirements of
dimensional accuracy and performance.
The design and manufacturing of the tools directly influence
Tool for a component Tool with Tool with stepped the tolerances of the components. Tolerances of shape and
stepped die
with 1 cross section conical die position are mainly influenced by the tool assembly. They
are governed by the clearances between punches and die or
punches and core rods respectively. For parts with several
split punches (multi level parts) the clearances add up to re-
duce the total accuracy. Tolerances in height are influenced
by the stiffness of the compacting or sizing presses and are
Tool for a component Tool with double Tool with split die
with multi cross top punch for a typically between 0.1 and 0.2 mm. Closer tolerances as de-
section component with
multiple cross
scribed above (Figure 2) can be attained by additional ma-
section chining operations. The small distortion caused by sintering
Figure 2 process can be corrected by sizing (cold repressing) of the
parts. Depending on density and material of a part an im-
provement of the dimensional quality can be achieved from
e.g. ISO/IT 8-9 to ISO/IT 6-7. An additional advantage of
the sizing step is the increase in density and improvement
of the surface quality. Additional influences on the dimen-
sional accuracy of a component are caused by subsequent
surface or heat treatment operations.
29
Surface Quality on PM Parts (ISO 23519)
Rough
Figure Processing Condition
Rt Ra
a) St 50 fine turned 10.7 1.28
b) St 50 grinded 4.2 0.6
c) SINT-C 00 as sintered 28 1.9
d) SINT-C 00 sized 10.6 1.22
Table 1
Surface roughness measured on different processing conditions
of steel and PM parts (examples)
30
500 µm
10 µm
b) St 50 grinded (Pt ~ 6)
500 µm
10 µm
II
Contact Area in %
ness Values in μm
at Cutting Depth c
Rz Rpk Rk 1 μm 2 μm 4 μm
8.2 4.5 5.4 <1 6 12
3.6 1.3 1.4 <1 71 100
18 1.4 1.4 <1 56 72
7.8 0.8 0.6 96 98 100
31
Hardness Comparison Table
32
Tensile Vickers Brinell Rockwell Hardness
Strength Hardness Hardness
Rm HV (F>98 N) HB HRC HRA HRB HRF
1155 360 342,3 36,6 68,7
33
Design Guidelines I
A ≥ 2 mm B ≥ 2 mm
C ≤2xA D ca. 3 x ø 1
R 0.3 - 1.5 α max. 30°
N 0.01/1 mm
A ≥ 1 mm C ≤ 0.2 D
Round apertures
preferred. Version A or B preferred Burr 0.15 permissible Replace sharp edges by
Wall thickness to avoid tangential junction (burr pockets) plain diameter
S = 2 mm min.
avoid
Tangential junction
34
Design Guidelines II
1. Axial tool design: fixed fill volume considering the fill factor
Limiting case for components with shoulder
lower density
area with
Max. overhang: ratio b / h ≤ 5
lower density
depending on:
area with
• the powder’s edge strength
• component density
• shoulder geometry
Factor 5 only applies to a rotary symmetrical shoulder
without profile. All influences that increase wall friction
(e.g. gear teeth) reduce possible overhang.
II
W
R
R
X
R
± 0.025
R
Tool partition
R
± 0.025 R
Tool partition
R
R
35
Design Guidelines III
Tool structure
Upper punch Die and core rod Lower punch 1 Lower punch 2 Tool parts assembled
36
Technical Support
The key to manufacturing high-performance, low-cost PM • Data Exchange with the customer for design via
parts is the tool design. To meet customer’s most challeng- Electronic Data Interchange
ing shape and dimensional requirements, GKN Sinter Met- • Additional technical conversation (meetings, calls…)
als offers comprehensive in-house tooling capabilities, in- • Finite Element Analysis to fit loading conditions vs.
cluding all major 3D-specific software. design
• GKN design of the part in Unigraphics (master model
By customizing fixtures and die sets, GKN tailors tooling and drawing)
concepts to your specific applications. The result? Consid- • Customer final check and approval before design
erations of customer’s need to ensure exceptional tool wear freeze of model and drawing
and long-term tool life. • Master model driven CAD parts for every following
process step
37
Markets
GKN Sinter Metals serves both automotive and industrial/consumer markets worldwide. As more and more companies dis-
cover the advantages of PM, our research and development team is hard at work leveraging years of product and process
expertise to find all-new cost-effective applications for a host of industries.
Miscellaneous Applications
• A/C compressor parts
• Alternator parts
• Bearings
• Bushings
• EGR valves
• Motor & drive parts
• Starter motor components Exhaust Systems
• Traction control system parts
• Wiper drive components • Bosses
• Electronic stabilization package parts • Flanges
38
GKN Sinter Metals is committed to helping customers across a variety of markets manufacture at peak efficiency and lower
overall costs. And, with the widest range of products, manufacturing capabilities and technical support in the PM industry,
GKN is the single-source supplier of choice to the lawn and garden/outdoor power equipment, home appliance and office
equipment, office and home furniture, and recreational vehicle markets, among others. Its key product lines include structural
components, bushings, bearings, gears, pumps, metal injection molded (MIM) and powder forged parts.
Small interacting parts, gears and bearings for drills, saws and other power
electronic tools belong to the wide product range of GKN Sinter Metals.
Refrigeration
GKN Sinter Metals manufactures a variety of exacting parts like valve plates
and compressor pistons for larger food refrigeration units and HVAC sys-
tems.
39
GKN - Innovation by Research and Development
The central R & D facility for research into all areas of pow-
der metallurgy covers an area of 3,500 m2.
40
State-of-the-art equipment and facilities are available.
II
41
GKN - Innovation by Research and Development
Static and dynamic test methods are available for the deter-
mination of soft magnetic characteristics.
Quality - QS Management
Quality management begins at the product concept stage and extends through design,
pre-production planning and the entire product life cycle. It involves ongoing education
programs, quality reporting and attention to detail every step of the way.
At GKN Sinter Metals quality is a multidisciplinary responsibility and highest priority for
each employee.
ISO 9001
ISO/TS 16949
ISO 14001
OHSAS 18001
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GKN Locations AMERICAS EUROPE
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