Apex Advanced Technologies,
Inc.
Presented by: Dennis Hammond
Optimizing Lubrication To
Maximize Density and Minimize
Ejection Forces
Presentation Outline
• Overview of Superlube™ characteristics
• Theory of maximizing density and minimizing
ejection forces
• Methods used to optimize lubrication
• Applications
– Minimizing ejection for large or
complicated parts at a G.D. of 7.0 g/cc
– Maximizing density and minimizing
ejection forces for pure iron and
performance alloys
• Conclusions
Superlube™ Characteristics
• Lubricant enters with the powdered metal as
a solid, transforms from a solid to a viscous
liquid with shear, temperature, and pressure
in the press
• Lubricant shear thins directly with shear
stress
• Direct results from solid to liquid
transformation
– High density achievable, 7.2 to 7.4 g/cc
– Low use levels required, typical 0.4% or
less
– Excellent lubricity, film of viscous liquid
versus slide on a solid particle
Direct results
• No special setup required
• Stroke rate can be increased
• Compressibility curve can be modified
to allow larger parts or lower tonnage
in the same press
• Tool wear improved due to better
lubrication and/or lowering of tonnage
• Surface finish improved
• Improved physical properties of final
part by 15 - 20%
Direct Results Cont.
• Powder movement to equalize green
density, near hydrostatic conditions in
compact
• Minimization of density gradients in the
part
• Elimination of micro cracking
• Reduces the risk of molding cracks
• Staggered decomposition in burn off
• Excellent dimensional stability of
sintered parts
Theory of Optimization
• Maximum green density is fixed by
the compressibility of the base
metal, volume of components
added, and TSI
• Excellent lubrication allows the
user to approach the maximum
green density for a composition at
a given TSI applied
Theory Cont.
• Using an internal Apex method, we
can determine the maximum practical
green density of a base metal at a
given TSI
• Theoretical density minus practical
density = volume of open space
• By targeting to fill this open space
with the volume of the components in
the mix, we have a basis for
calculation of total volume % achieved
Maximum Compressibility
of Various Base Metals
40TSI
50 TSI
60TSI
A-1000A
7.07
7.27
7.37
A-1000B
7.09
7.27
7.39
A-1000C
7.18
7.35
7.43
A-85HP
7.08
7.28
7.40
A-737SH
6.88
7.11
7.26
Maximum Compressibility
of Various Base Metals
40 TSI
50TSI
60 TSI
ASC100.29 7.10
7.29
7.39
ABC100.30 7.18
7.33
7.43
Astaloy 85 7.09
Mo
Astaloy
7.01
Mo
Astaloy
6.96
CrL
7.28
7.39
7.22
7.37
7.17
7.28
Maximum Compressibility
of Various Base Metals
Astaloy
CrM
Atomet
1001
Atomet
1001HP
Atomet
4001
Atomet
4401
40TSI
50TSI
60TSI
6.88
7.10
7.26
7.10
7.27
7.37
7.14
7.30
7.39
7.08
7.28
7.39
7.06
7.27
7.39
Theory Cont.
• Mobile lubricant is pressed to the
die wall due to the collapse of the
pores or closing of the open
space as the base metal is
compressed
• Serves as an internal and die wall
lubricant at the same time
Theory Cont.
• 98% to 100% volume fill has been found
to work effectively
• 99%to 99.5% volume fill is an optimum
target to achieve max. green density
and minimum ejection while
accommodating normal production
variability
• Predictability is robust and has been
proven in many production examples
FLN2-4405 TSI/ G.D./ Vol.%
.35% Superlube™
TSI
G.D. g/cc
Vol.%
44
7.2
98
47
7.25
98.7
49
7.28
99.1
50
7.3
99.4
54
7.35
100
Theory Cont.
• Some formulas need to have the
volume adjusted upward to take
maximum advantage of the
lubricant
• An Apex enhancer can be used
effectively to make volume
adjustments
• Key issues are, the volume
contribution of components
needed and the desired density
Common Formulation for FN-0205
Volume
Specific
Gravity
Volume
Contribu
tion
Contribution
97.06%
7.84
12.38
93.67%
Nickel
1.99%
8.85
0.23
1.70%
Graphite
0.60%
2.3
0.26
1.97%
PS1000b
0.35%
0.991
0.35
2.66%
Non-Iron %
6.33%
Ingredients
Iron
Max Iron %
Max
Practical
Green
Density
Mix %
93.75%
7.35
Volume
Achieved:
100.08%
by %
Common Formulations
Calculated G/D,TSI, A-1000C,.35%
Superlube™
• FN-0205:
– 99% vol. 7.31g/cc, 46 TSI
– 100%vol. 7.39g/cc, 52 TSI
• FN-0208:
– 99% vol. 7.23 g/cc, 41TSI
– 100% vol. 7.30 g/cc, 45TSI
• FC-0208:
– 99% vol. 7.21 g/cc, 41TSI
– 100% vol. 7.29 g/cc, 45TSI
Enhancer Characteristics
• Clean burning, no ash
• Primary function to fill space,
secondary lubrication
• Needs to deform and slide with the
metal and lubricant movement
• Helps to maintain green strength
• Compatible with mixing, compaction
and processing
• Favorable cost, specific gravity ratio
Applications
• A tall or complex part of lower G.D. - 6.9
to 7.1 g/cc can be made successfully by
adjusting the volume fill upward by
using an enhancer.
• Benefits include lowering ejection
forces, minimized die wear, part
breakage, internal cracking or lower
compaction tonnage to achieve the
desired G.D.
Compaction Force vs. Volume %
on Formulation FLN2-4405 @ 7.0 g/cc G.D.
Compaction Force (TSI)
42
41
40
39
38
37
36
35
Tsi
0.75%
Keno
lube
42
0.75%
91.98%
Acra wax
40
Lube
(WT. %)
Enhancer (WT. %)
96.93%
98.44%
98.94%
35
37
37
36.5
.35
100.60% 101.64%
37
41
.35
.35
.35
.35
.35
.15
.35
.50
.65
.80
3500
2100
3300
2000
3100
1900
2900
1800
2700
1700
2500
1600
2300
1500
2100
1400
1900
1300
1700
1200
1500
Volume %: 91.98% 96.93% 98.44% 98.94% 100.60%101.64%
0.75% 0.75% Lube:
- 0.35% 0.35% 0.35% 0.35% 0.35% 0.35%
Keno Acra Enhancer 0.15% 0.35% 0.50% 0.65% 0.80%
lube
wax :
Peak 2608
Slide 1875
2398
3018
2255
2394
2186
2005
1854
2025
1992
1550
1400
1400
1325
1175
1100
Slide (LbF)
Peak (LbF)
Volume % vs. Peak and slide
on Formulation FLN2-4405 at 7.0 g/cc G.D.
Green Dimensional
Change
Enhancer Effect on Green Dimensional Change on Formulation
FLN2-4405 @ 7.0 g/cc G.D
0.50%
0.40%
0.30%
0.20%
0.10%
0.00%
0.75% 0.75% Lube: 0.35%
Keno Acra Enhancer: -
Dimensional Change 0.19% 0.17%
0.17%
0.35% 0.35%
0.15% 0.35%
0.35% 0.35%
0.50% 0.65%
0.35%
0.80%
0.17% 0.17%
0.19% 0.17%
0.20%
Green Strength (PSI)
Enhancer Effect on Green Strength on Formulation
FLN2-4405 at 7.0 g/cc G.D.
2100
2000
1900
1800
1700
1600
1500
1400
0.75% 0.75% Lube:
0.35% 0.35% 0.35% 0.35% 0.35% 0.35%
Keno Acra
Enhancer: 0.15% 0.35% 0.50% 0.65% 0.80%
lube wax
Green Strength 2024 1710
1580 1480 1827 1888 1911 1922
Applications cont.
• A pure iron part can be made using the
same concept, 98-100% volume fill
pressed to the desired TSI
• A-1000C was filled with a combination
of Superlube™ and Apex Enhancer at
various volume %, ejection (peak and
slip) were measured as well as density
• Possible applications - magnetic parts,
etc
Peak/Slide (TSI)
Enhancer Effect on Peak, Slide, and G.D.
on A1000C at 60TSI
2600
7.44
2400
7.41
7.38
2200
7.35
2000
7.32
1800
7.29
1600
1400
Volume%
7.26
97.34%
98.56%
100.00%
100.53%
101.29%
slide
2583
1850
1625
1683
1458
G.D
7.37
7.42
7.41
7.38
7.30
7.23
A-1000C Comparison Acrawax
versus Apex 60TSI
Wt %
Vol.%
Peak
LbF
Slide
LbF
Acrawax
.51%
98.56%
3727
2533
Apex
.35% lube
.14% enhancer
Acrawax
.49%
98.56%
3257
1850
.71%
100%
3113
2533
Apex
.35% lube
.31% enhancer
.66%
100%
2776
1625
High Density Applications
• High density parts can be made by
using the lubricant alone or with
small amounts of enhancer
• Many applications are running in
production at 7.2 - 7.4 g/cc
• Lubricant use level ranges from
0.27% to 0.45% for steel parts
High Density Applications Cont.
• FC-0208 NAH ABC 100.30, 0.4 wt% lube,
9# part, 54 mm height, 7.2 g/cc, 45 TSI,
99.3%volume, lowered press TSI
• FC-0208 NAH ABC 100.30, 0.4% lube, 40
mm height, 51 mm O.D. 7.3 g/cc, 55 TSI
99.9% volume, large part, high density
High Density Applications
Cont.
• FLC-4608, A-737SH, 0.45 wt% lube, 50
mm height, 51mm O.D. gear, 7.2 g/cc,
51TSI, 99.4% volume, large part, high
density
• Astaloy Mo, 2% Ni, 0.3% Graphite,
0.35% lube, 0.15% enhancer, 20 mm
height, 7.27 g/cc, 49TSI, multi-level with
hole 99.0% volume fill
High Density Applications Cont.
• FLN2-4405, A-85HP 0.35% lube 7.29 - 7.33
g/cc, 49-52TSI, 6mm - 51mm height, 14
applications helical gear, straight gears,
multi- level parts, counter bores, ~9999.4% volume fill
• A-85HP,2% nickel, 0.35% lube, .25%
graphite,0.15% enhancer, 7.3 g/cc, 51TSI,
25 mm height, gear, 99.5% volume fill,
elimination of double press
High Density Applications Above
Target Range
• Excellent Lubricity with .25-.4%
• High Density 7.25 g/cc and above
• Metal restricted from maximum
compressibility
• Reduced hydrostatic effect
• Predictability of density achievable but
TSI predictions are difficult
• Formulas with 3% additions and higher
are most likely to be over 100% fill
Application Summary
• High Density 7.2 - 7.4 g/cc
• Elimination of double press, double sinter
• Highly efficient, cost effective copper
infiltration
• Elimination of cracks, parts 6.9-7.4 g/cc
• Minimization of ejection problems, 6.9-7.4
g/cc
• Minimization of die wear,6.9-7.4 g/cc
• Improved part performance and surface
finish
• High nickel based parts without blistering
Lube and Density Prediction
• By knowing the compressibility of the
metal involved, the components, the
part length, size, and the desired
density, we can calculate the lube or
enhancer needed
• From this calculation, achievable
density verses TSI can be predicted
• Predictability has been robust and a
very viable tool for optimizing, new part
development, and problem solving
Conclusions
• Maximum density and minimum
ejection forces are not exclusive to
each other, they can be obtained at the
same time
• A lubricant that transforms from a solid
to liquid changes the rules compared to
conventional lubricants
• Compressibility of the base metals
varies significantly, and it is a critical
factor in the results achievable
Conclusions Cont.
• High density 7.2 - 7.4 g/cc can be
achieved with no special equipment or
procedures with good ejection
characteristics
• Lower density can be successfully
made with lower tonnage, lower
ejection forces, and good green
strength
• Desired lubrication and density are
predictable using developed
calculation methods
Conclusions Cont.
• We can approach the upper
compressibility limit for the base metal
at a given TSI with alloy components
included
• By designing a lubricant system for a
given application, the breadth of parts
that can be made can vary from small to
large, moderate to high density, and
simple to complex.
• Theory and practice are transferable to
other P/M parts Al, Brass,Bronze, and
S.S.