Hoeganaes Corporation

Kalathur S Narasimhan

Nikhilesh Chawla

Frederick J Semel

The present invention provides iron-based infiltration methods for manufacturing powder metallurgy components, compositions prepared from those methods, and methods of designing those infiltration methods. Iron-based infiltration methods table include the steps of providing an iron-based infiltrant composed of a near eutectic liquidus composition of a first iron based alloy system and an iron-based base compact composed of a near eutectic solidus powder composition of a second iron based alloy system. The base compact is placed in contact with the infiltrant and heated to a process temperature above the melting point of the infiltrant to form a liquid component of the infiltrant. Lastly, the base compact is infiltrated with the liquid component of the infiltrant. During infiltration, the liquid component of the infiltrant flows into the pores of the base compact.

Methods of preparing high density powder metallurgy parts by iron based infiltration

The present invention is directed to improved compaction techniques for use in powder metallurgical applications using lower temperatures and pressures than are traditionally used in the field.

Compaction methods

Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based powder, that constitutes the major portion of the composition. A silicon carbide-containing powder is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a &ldquo;green&rdquo; compact that is then sintered, preferably at relatively high temperatures.

Metal-based powder compositions containing silicon carbide as an alloying powder

Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based or nickel-based powder, that constitutes the major portion of the composition. Silicon carbide is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a &ldquo;green&rdquo; compact that is then sintered, preferably at relatively high temperatures.

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Moorestown, NJ, United States of America

Kalathur S Narasimhan