Embed Size (px)
Citation preview
PM Aluminium Materials
Why PM Aluminium? - Do itAdvantages of Powder Metal (PM)
Powder metal processing is a highly cost effective method of producing simple and complex parts at, or close to, fi nal dimensions. With tight dimensional tolerances, minimum scrap loss and fewer secondary machining operations, PM Aluminium is uniquely positioned to provide value to its customers.
The ability to broadly control the powder constituents and process parameters allows the physical and mechanical properties of manufactured components to be tailored to the application. In fact, material de-velopments in Al-Si, Al-Zn and Metal Matrix Composites have allowed powder metal to provide materials with superior properties than those available via other aluminium processing methods.
Powder metal aluminium parts have an excellent response to heat treatment, for increased wear and ten-sile strength. The manufacturing process also has a high level of dimensional control and reproducibility through sizing operations.
2
t the Light Way!
3
Easy Fabrication / Machinability
Aluminium is readily turned, milled or bored. In ma-chining operations aluminium displays high cutting speeds, smooth surface fi nish and allows for outstan-ding tool life
Surface Treatment
For many applications no further protective or decora-tive coatings are required, but when needed mechani-cal, chemical, electrochemical, and paint fi nishes can all be used. In addition, anodising treatments can en-hance corrosion resistance and provide a wide range of color variation.
Joining
Almost any method of joining is applicable; riveting, welding, brazing or soldering. Adhesive bonding of aluminium is also used in many aerospace, automo-tive and construction applications.
Economically viable
Though aluminium materials are typically more expen-se than other common metals, this is often offset by a number of direct and indirect processing and handling costs; less weight of material used, higher machining speed, reduced shipping weight, etc
Recyclable
Aluminium is 100 % recyclable with no downgrading of its qualities. In addition, recycling aluminium only requires 5 % of the energy needed to produce alumini-um from raw materials.
Lightweight
Aluminium is approximately 1/3 the weight of iron, steel, copper or brass making it the metal of choice where mass is a concern
Strong
The strength-to-weight ratio of aluminium, outperforms other materials. Alloying and heat treat can markedly increase mechanical properties
Corrosion Resistant
A thin oxidized fi lm forms on the surface when expo-sed to air, providing excellent corrosion resistance
Ductile at low temperatures
Unlike steel, aluminium increases in tensile strength and retains excellent toughness at low temperature
Resilient
Aluminium behaves elastically under static and dyna-mic loads. It also has excellent sound and vibration dampening properties
Heat / Electrically Conductive
Conducts heat better than other common metals (about 3 times that of steel). Its electrical conductivity is approximately 62 % of copper at 1/3 the weight
Non-Magnetic
This property makes aluminium useful for electromag-netic shielding
Aluminium Powder Metal - The Unique Powder Metal versus Die Casting
PM has homogeneous part composition
No issues with pre-solidifi ed material, shrink porosity or areas of slow solidifi cation
No large porous sections or entrapped porosity
Die castings have a fi ne grain structure skin (.125” thick) with much larger grain structure in thick sections
PM has better cosmetics
No swirls or knit lines due to molten metal fl ow
No gate, vent scars, ejector pin marks or fl ash
No degradation due to heat checking on die cavities
PM has longer tool life
150k-175k shots in die casting where PM can have over a million parts off tooling
PM tooling cost is normally a one time expense for the life of part, where die cast can be an annual expense. This can lead to signifi cant savings (10-15 times the PM tooling cost) over the part's life
4
Properties of PM
5
PM has improved part integrity
No entrapped porosity due to die, shot tip lube or air poro-sity
No pre-solidifi ed metal or alloy separation in the melt
PM has fewer process variables
No shot speed variation, shot tip wear, shot sleeve wear or gate wear impacting fl ow pattern
No plugged cavity vents
No melt temperature variations or variations between cavities
No melt cleanliness due to improper drossing or fi lling of fur-naces
PM has less process waste
No fl ash, trim waste or foundry scrap
6
Metal powder +alloying elements Mixing
Sintering
Sizing
Secondaryoperations
Sintered Aluminium - Materials and ProSintered aluminium presents engineers with a material soluti-on for reduced weight, near net shape forming capability, and a wide array of mechanical properties through various alloy selections.
Materials are available in 2000, 6000, and 7000 series sys-tems as well as Al-Si, Metal Matrix Composite and high density systems which possess improved wear resistance and enhan-ced properties. Properties can often be tailored through the use of a broad ran-ge of materials and processing conditions. Sintered aluminium provides the designer an alternative pro-cessing solution over aluminium die cast, extrusions and ma-chined parts at a competitive price.
1.) Raw Material
GKN offers aluminium materials in a variety of chemistries to provide a wide range of properties to match the demanding needs of the marketplace. Materials include 2014, 6061, 7075, Al-14Si, and Al MMC (Aluminium Metal Matrix Composite) as well as several developmental materials to help meet our gro-wing customer needs. Material development is a key differen-tiator and we are able to offer unique aluminium compositions and blends to our customers
2.) Pressing/Compaction
GKN has a variety of special presses with multi-level technolo-gy to compact parts in the density range of 2.45 to 2.65 g/cm3 (88 - 95% of theoretical density). Aluminium powder is softer than iron based powder materials which allows for compaction at low pressures resulting in less wear and exceptional tooling life.
3.) Sintering
For sintering the green compacts, we use precision controlled continuous furnaces which contains lubricant burnout, sin-tering, and gas quench sections. Sintering temperatures are relatively low (typically at about 600 °C) and the atmosphere is 100% high purity nitrogen. Each furnace is capable of produ-cing millions of parts annually.
Deburring/Tumbling
7
Pressing
Homogenization/Solutionizing
Finishedaluminium part
ocessUnlike traditional iron PM materials, GKN has some alumini-um PM compositions that densify signifi cantly during sintering resulting in sintered densities in excess of 98 % of theoretical density.
4.) Homogenization/Solutionizing (optional)
Solutionizing is a heat treatment conducted just below the li-quidus to homogenize the material. The parts become more ductile after this operation which enhances their response to subsequent sizing processes where density and strength are enhanced.
5.) Sizing
GKN employs sizing/coining operations as needed to densify and meet dimensional targets and tolerances, typically to the extent that no machining is necessary. Sizing of some materials increases the density which enhances the mechanical proper-ties of the part.
6.) Deburring/Tumbling
Is used to removed sharpe edges created during sizing and to provide a uniform surface appearance, while cleaning the part of sizing.
7.) Artifi cial Aging (optional)
If the parts undergo solutionizing, they are subsequently hea-ted to low temperature for a 24 hour period to artifi cially age the material and quickly build hardness and strength. This would normally take months if the parts were left to age at room tem-perature.
8.) Secondary Operations
Secondary operations can include machining if dimensional targets can't be met with sizing. They also include impregnati-on, anodizing, alodine, or other surface treatments.
optional
PM Aluminium - Applications
8
Automotive Applications
Engine Cam Caps
For automotive and Industrial applications
Unique “Z-Loc” feature that offers signifi cant cost benefi ts for cap assembly over dowel pins
Displaced aluminium die-castings
Ability to form parts with complex geometries and oil grooves without machining
Variable Valve Train
Sprocket, Rotor and Stator
Future development
Torque Converter OWC retainer Cap
Provides required functionality while reducing weight of the application
Stamping conversion
9
Non-Automotive Applications
Corrosion resistant and lightweight
Small Engine Con Rods
Levers for Lawn and Garden applications
Bushings, spacers, latches, gears, etc.
Electronics
Hydraulic components
Thrust plates for gear pumps
Gears for external and internal (crescent and G-rotor) pumps (current development)
Machine, Prototyping and Forging blanks
A wide variety of material blanks for machined parts, prototype parts, and forgings
PM Aluminium - Materials
10
Standard Reference I Typical Properties (References)
MPIFDensity [g/cm3]
Typical compositionTypical Density [g/cm3]
Hard-ness HB
UTS [MPa]
FEL [MPa]
YS 0,2 [MPa]
EL [%]
E [GPa]
Remark
N/A 2.45 - 2.60 Al4.5Cu0.5Mg0.7Si 2.60 60 160 60 130 1.5 50
N/A 2.45 - 2.60 Al4.5Cu0.5Mg0.7Si 2.60 75 300 80 280 1 57 T6 heat treated
N/A 2.50 - 2.60 Al1.0Mg0.5Si0.2Cu 2.55 40 160 1) 100 2
N/A 2.50 - 2.60 Al1.0Mg0.5Si0.2Cu 2.55 70 240 1) 210 1 T6 heat treated
N/A 2.55 - 2.65 Al2.5Cu0.5Mg14Si 2.62 80 200 100 150 1 79
N/A 2.55 - 2.65 Al2.5Cu0.5Mg14Si 2.62 115 320 80 300 < 1 79 T6 heat treated
N/A 2.74 - 2.78 Al5.5Zn1.6Cu2.5Mg 2.76 100 315 80 270 1.2 65
N/A 2.74 - 2.78 Al5.5Zn1.6Cu2.5Mg 2.76 135 420 120 410 1 65 T6 heat treated
Aluminium Metal Matrix Composite Materials (Al MMC)2)
N/A 2.68 - 2.72 AlXCuXMgXCeram 2.70 100 270 1) 210 3 50
N/A 2.68 - 2.72 AlXCuXMgXCeram 2.70 110 310 1) 280 1.5 55 T6 heat treated
1) Being evaluated 2) Other MMC materials are currently under development
Elongation - Total strain measured with a 25 mm gauge length extensometer that remained attached to the sample through to fracture.
FEL - Based on 10,000,000 cycles of completely reversed stress using an R.R. Moore type of instrument. Specimens prepared and polished in accordance with ASTM standard B925-08.
Young’s Modulus - Measured in accordance with ASTM standard E111-04
Yield Strength - Measured at an offset of 0.2 % strain.
Density - Measured in accordance with ASTM standard B328-96.
11
Chemical Composition (Standard) Standard Reference II
Al [wt.-%]
Cu [wt.-%]
Zn [wt.-%]
Si [wt.-%]
Mg [wt.-%]
Others [wt.-%]
GKN SM Material
Code
DIN 30903SINT-
ASTM B595-95
Bal. 4.0 - 5.0 - 0.7 0.5 <0.5 PMET AL2014 D73/E73 ACT1-2014 type II
Bal. 4.0 - 5.0 - 0.7 0.5 <0.5 PMET AL2014 T6 E73 ACT6-2014 type II
Bal. 0.2 - 0.5 1 <0.5 PMET AL6061 E73 AT1-6061 type II
Bal. 0.2 - 0.5 1 <0.5 PMET AL6061 T6 E73 AT6-6061 type II
Bal. 2.0 - 3.0 - 13 - 15 0.5 <0.5 PMET AL14Si N/A N/A
Bal. 2.0 - 3.0 - 13 - 15 0.5 <0.5 PMET AL14Si T6 N/A N/A
Bal. 1.6 5.0 - 6.0 - 2.5 <1 PMET AL7075 N/A N/A
Bal. 1.6 5.0 - 6.0 - 2.5 <1 PMET AL7075 T6 N/A N/A
Bal. X - - X <10 PMET ALMMC1 N/A N/A
Bal. X - - X <10 PMET ALMMC1 T6 N/A N/A
UTS: Ultimate Tensile Strength FEL: Fatigue Endurance Limit YS: Yield StrengthEL: Elongation E: Youngs Modulus
About GKN Sinter Metals
GKN Sinter Metals – a wholly owned subsidiary of U.K.-based GKN plc, a global industrial company – is the world’s largest producer of precision powder metal products. With a focus on superior delivery, quality and total solutions, the company offers exten-sive technical expertise in design, tes-ting and various process technologies. GKN Sinter Metals offers a full range of more than 10,000 complex shape, high strength products for the automotive, commercial vehicle, home appliance, lawn and garden, offi ce equipment, power tool, recreational vehicle and process industry markets.
The company’s global footprint spans more than 13 countries across fi ve con-tinents. GKN Sinter Metals is in close proximity to its customers with more than 30 global locations and a work-force of approximately 5,500 emplo-yees.
For more information about GKN’s world of solutions visit www.gknsintermetals.com
Production Countries
ArgentinaGKN Sinter Metals de Argentina S.A.Ruta Nac. 5 Km. 159,5(B6622GKA) Chivilcoy – Bs. As.Argentina
Phone: *54-11-5368-3700E-mail: [email protected]
BrazilGKN Sinter Metals Ltda.Av. Emancipacão, 4.500 - Santa EsmeraladaCEP 13186-542Hortolandia – SP – Brazil
Phone: *55-19-2118-9400E-Mail: [email protected]
CanadaGKN Sinter Metals – St. Thomas Ltd.7 Michigan BoulevardSt. Thomas, OntarioCanada N5P 1H1
Phone: *1-519-631-4880E-mail: [email protected]
ChinaGKN Sinter Metals – DanyangNumber 7 Mechanical Industry ParkDanyang Development ZoneDanyang, China
Phone: *86-511-86-885-556E-mail: [email protected]
GermanyGKN Sinter Metals Engineering GmbHKrebsöge 1042 477 RadevormwaldGermany
Phone : *49 2191-693-0E-mail : [email protected]
GKN Sinter Metals Filters GmbHDahlienstraße 43P.O.Box 152042 477 RadevormwaldGermany
Phone: *49 2195-609-27E-Mail: feedback@gkn-fi lters.com
IndiaGKN Sinter Metals Ltd.146, Mumbai Pune RoadPimpri, Pune 411 018 Maharashtra, India
Phone: *91-20-2742-6261, 6262, 6263E-mail: [email protected]
ItalyGKN Sinter Metals SpAFabrikstraße 539 031 Bruneck (BZ)Italy
Phone. *39-0474-570211E-mail: [email protected]
North AmericaGKN Sinter Metals3300 University DriveAuburn Hills, Michigan 48326-2362 USA
Phone: *1-248-371-0800E-mail: [email protected]
GKN Sinter Metals (PM Aluminium Plant)407 Thornburg DriveConover, NC 28613
Phone: *1-828-466-5019E-mail: [email protected]
South AfricaGKN Sinter Metals – Cape TownP.O.Box 156Sacks CircleBellville, 7530South Africa
Phone: *27-21-950-6200E-mail: [email protected]
GKN Sinter Metals Sales Offi ces Worldwide
ChinaE-mail : [email protected]
FranceE-mail: [email protected]
JapanE-mail: [email protected]
KoreaE-mail: [email protected]
SpainE-mail: [email protected]
SwedenE-mail: [email protected]
United KingdomE-mail: [email protected]
United StatesE-mail: [email protected]
© Copyright by GKN Sinter Metals - Rev. 1.0
