NOC Metals Ready-to-Press Powder
April 2024 Ready-to-Press Powder Catalog
YG6UF
Co
6%
HRA
92.7 to 93.7
C3
Co
6%
HRA
92.4 to 93.0
YG8UF
Co
8%
HRA
92.1 to 93.1
C2
Co
6%
HRA
91.7 to 92.2
YG10UF
Co
10%
HRA
91.6 to 92.2
YG12UF
Co
12%
HRA
91.3 to 92.3
YG11X
Co
11%
HRA
91.3 to 91.7
YG10X
Co
10%
HRA
91.3 to 91.7
YG6
Co
6%
HRA
90.5 to 91.5
YG8.5
Co
8.5%
HRA
90.0 to 90.6
YG5C
Co
5%
HRA
89.8 to 90.6
YG6C
Co
6%
HRA
89.4 to 89.8
YG15X
Co
15%
HRA
89.2 to 90.2
YG11
Co
11%
HRA
88.5 to 89.5
YG12D
Co
12%
HRA
88.2 to 88.8
YG10C
Co
10%
HRA
87.0 to 87.8
YG10.5C
Co
10.5%
HRA
87.0 to 87.8
YG6EC
Co
6%
HRA
87 to 88
YG9.5C
Co
9.5%
HRA
86.5 to 97.8
YG8.5EC
Co
8.5%
HRA
86.5 to 88.5
YG15C
Co
15%
HRA
85.6 to 86.16
YG10EC
Co
10.5%
HRA
85.5 to 86.5
YG15D
Co
15%
HRA
85 to 86
YG18
Co
18%
HRA
84.3 to 86.3
This is a quick overview of our most popular Ready-to-Press Powder products, all ready for immediate shipment.
For detailed ’April information on additional RTP (including full chemical analysis and lab test quality certificates) or current pricing and availability, please use the contact form below.
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April 2024
Understanding Ready-to-Press Powder
A Comprehensive Guide by NOC Metals
Ready-to-Press Powder - An Overview
Ready-to-Press (RTP) powder refers to a stage in the powder metallurgy process where the initial raw powder material, such as tungsten carbide powder, has been mixed with a binder or other additives to create a composite that’s ready to be pressed into a shape. This material is often called a “feedstock,” and it’s designed to be easily shaped in the subsequent pressing process.
The binder, often paraffin wax or a polymer-based material, serves to hold the powder particles together and give them some plasticity. This allows the powder-binder mixture to be pressed into a die to form a specific shape, known as a green body. The type and amount of binder used can be varied based on the specific needs of the application, including desired properties of the final product, the pressing method, and the sintering conditions.
It’s important to understand that the binder is a temporary addition. After the green body is formed, the binder is removed in a process called debinding or pre-sintering, which can involve heating the body to vaporize the binder or soaking it in a solvent. The green body is then sintered to achieve full density and hardness.
While the basic concept is straightforward, creating a good RTP powder is a precise science. The powder and binder must be thoroughly mixed to ensure homogeneity, and the particle size distribution of the powder can greatly affect the pressing and sintering behavior. Different applications may also call for additional additives in the RTP powder to enhance certain properties, such as improving hardness or toughness in the final product.
RTP powder is the ready-to-use material that results from combining tungsten carbide powder (or another metal powder) with binders and other additives. This formulation is carefully designed to allow for efficient pressing into a desired shape, followed by binder removal and sintering to create the final product.
The Distinction: Tungsten Carbide Powder vs. Ready-to-Press Powder
Tungsten Carbide Powder and Ready-to-Press (RTP) Powder, while intrinsically related, serve distinct purposes within the manufacturing process.
Tungsten Carbide Powder is the raw, unprocessed form of tungsten carbide. It’s a fine, gray powder that consists solely of tungsten carbide particles. It has the unique properties of tungsten carbide, such as high hardness and wear resistance, but in its raw form, it lacks the cohesion necessary for shaping into a solid part.
On the other hand, Ready-to-Press (RTP) Powder is a stage further along the manufacturing process. It’s a mixture of tungsten carbide powder and various binders and additives that give the powder certain properties that make it easier to process. The binder provides plasticity, allowing the powder to hold its shape when pressed in a die, and additional additives can be included to alter the properties of the final product.
The advantage of RTP powder lies in its preparedness for the next manufacturing step: pressing. With the addition of binders and other additives, RTP powder can be formed into a wide variety of shapes and sizes with relative ease. This is beneficial in manufacturing because it streamlines the process and allows for greater complexity and precision in the parts being made.
However, this does not mean that RTP powder is universally superior. The choice between using raw tungsten carbide powder and RTP powder depends largely on the specific needs of the manufacturing process. If you’re aiming for a specific shape that requires pressing, then RTP powder would likely be your choice. However, if you’re using a method that doesn’t involve pressing, such as certain types of additive manufacturing, then raw tungsten carbide powder could be more appropriate.
While both tungsten carbide powder and RTP powder have their uses, the choice between them depends on the specific requirements of the manufacturing process. RTP powder is essentially a prepared or ‘pre-processed’ version of tungsten carbide powder, designed for ease of use in pressing applications.
The Composition and Characteristics of Ready-to-Press Powder
The composition of Ready-to-Press (RTP) powder is a careful balance of several different components. While the primary ingredient is often a metallic powder such as tungsten carbide, a variety of additives are mixed in to give the powder the desired characteristics for pressing and sintering.
1) Tungsten Carbide: This is the primary structural component of the powder, providing the key characteristics of hardness and wear resistance in the final product. The specific particle size and distribution of the tungsten carbide in the mix can greatly affect the behavior of the powder during pressing and sintering.
2) Binder: The binder is the component that gives the powder its plasticity, allowing it to hold its shape when pressed. This is often a wax or a polymer material. The type and quantity of binder used can be varied to adjust the pressing behavior of the powder.
3) Additives: Depending on the specific needs of the application, additional components may be included in the RTP powder. These can include other metal powders to form a composite material, or specific additives to enhance certain properties in the final product, such as improved hardness or toughness.
In terms of physical characteristics, RTP powder is designed to have good flowability, allowing it to easily fill the die during pressing. It should also have a high packing density to reduce the porosity of the pressed part and to maximize the strength of the final product. Additionally, it needs to have a controlled shrinkage rate during sintering to avoid warping or cracking of the part.
The ultimate aim is to create a powder that is easily processed into a green body, and subsequently sintered into a finished product with the desired physical and mechanical properties. Every aspect of the powder’s composition and characteristics is carefully designed with this end goal in mind.
Top 7 Key Steps in the Production of Ready-to-Press Powder - A Comprehensive Guide
1) Selection of Raw Materials: The first step is to select the appropriate raw materials, which will largely be determined by the desired properties of the final product. This generally includes a base metal powder, such as tungsten carbide, as well as a binder material and any other additives that may be required.
2) Blending: The raw materials are thoroughly mixed together to ensure a homogeneous blend. This step is crucial because it ensures that every part of the powder mixture has the same composition, which in turn leads to uniform properties in the final product.
3) Milling: After blending, the mixture undergoes milling to reduce the particle size and ensure a uniform particle distribution. Milling also enhances the homogeneity of the mixture by promoting more intimate contact between the different components.
4) Spray Drying: The milled mixture is then fed into a spray dryer. This process involves atomizing the slurry into small droplets and then drying these droplets in a hot gas stream. The result is a free-flowing powder with a spherical particle shape, which improves the powder’s flowability and packing density.
5) Screening: The dried powder is then screened to remove any agglomerates and to classify the powder by particle size. This ensures that the powder will fill the die evenly during pressing, leading to a more consistent final product.
6) Quality Control: At several stages during the production process, samples of the powder are taken and tested to ensure that it meets the required specifications. This may include testing for chemical composition, particle size distribution, flowability, and compressibility, among other properties.
7) Packaging and Storage: Once the powder has passed all necessary quality control checks, it is packaged for transport and storage. It is essential to protect the powder from moisture and contamination to maintain its properties.
Please note that this is a high-level view of the process, and the exact details can vary based on the specific requirements of the powder being produced. However, the general steps of selecting the raw materials, blending, milling, spray drying, screening, and quality control are common to most RTP powder production processes.
Ready-to-Press Powder Role in Powder Metallurgy and Sintering
In powder metallurgy, Ready-to-Press (RTP) powder plays a crucial role as it facilitates and optimizes the press-and-sinter process. The pressing process involves applying pressure to the RTP to consolidate it into a green compact, which is the initial form of the desired part. The green compact is then sintered, a heat treatment process, to enhance its properties.
1) Pressing: In the case of tungsten carbide parts, the RTP is loaded into a die that matches the desired shape of the final part. Under high pressure, the powder particles get close enough to create bonds between them, leading to the formation of a coherent solid known as a green body or green compact. The binder content and flowability of the RTP ensures that it evenly fills the die, leading to a green compact with consistent density and geometry.
2) Debinding: After pressing, the green compact undergoes a debinding stage. This step involves the removal of the binder material that was mixed with the tungsten carbide powder to form the RTP. Debinding can be carried out thermally or using a solvent. It’s a crucial step to prepare the part for sintering.
3) Sintering: After debinding, the compact undergoes sintering, a heat treatment process where it is heated to just below the melting point of the main metal component (tungsten carbide in this case) in a controlled atmosphere. During sintering, the contact points between the powder particles coalesce, leading to an increase in strength and hardness of the part.
The use of RTP streamlines this process, as the composition of the powder has already been fine-tuned during its production. As such, the green compacts can reliably be pressed and sintered to achieve the desired properties in the final part.
RTP is important not only for its role in the efficient production of parts but also in maintaining consistent quality. Its optimized properties ensure repeatability in manufacturing, reducing the potential for defects and wastage, thereby increasing overall productivity and efficiency in the production of tungsten carbide parts.
5 Key Steps in the Press-and-Sinter Process: A Beginner's Guide
The press-and-sinter process, integral to the production of many metallic parts, predominantly those made from metal powders such as tungsten carbide, involves a series of specific steps to convert raw materials into a final product. This process is favored for its ability to produce complex shapes at a low cost.
Step 1: Mixing
In the beginning, we have the blending of raw material powders. For example, with tungsten carbide parts, we mix tungsten carbide and cobalt powders. The mixing step ensures a homogeneous blend of powders, which is crucial to achieve consistent properties in the final part. Additionally, a lubricant is often added to ease the subsequent steps.
Step 2: Compacting
Following mixing, the powder is compacted or pressed into a die to achieve the rough shape of the final part, hence the term “pressing”. The die, designed based on the final part’s shape, exerts a high force on the powder, causing the particles to bond together through mechanical interlocking and cold welding. The result of this stage is called a ‘green compact’ or ‘green part’.
Step 3: De-lubrication
The green part then undergoes a de-lubrication process or ‘debinding’, where it is heated in a controlled environment to remove the lubricant used during pressing. This process must be done carefully to avoid defects in the part.
Step 4: Sintering
The debound part is next sintered, or heated to a temperature below the melting point of the main constituent, but enough to allow for diffusion processes to occur. This step imparts strength to the part by creating metallurgical bonds between particles. For tungsten carbide, the sintering process involves heating in a vacuum or inert atmosphere to prevent oxidation and maintain the part’s properties.
Step 5: Post-Sintering Operations
Finally, the sintered part may undergo post-sintering operations, such as re-pressing, machining, or grinding, to achieve the desired dimensional accuracy or surface finish.
This procedure forms the foundation of the powder metallurgy industry. However, specifics can vary depending on the materials used, the desired properties, and the final product’s application. For instance, tungsten carbide parts would require unique considerations due to the material’s inherent properties, like high melting point and hardness.
Applications and Use Cases for Ready-to-Press Powder
RTP powders, particularly those derived from tungsten carbide, are extensively utilized across a diverse range of industries. The inherent advantages of these powders – their ease of use, consistent quality, and the resultant precision and durability of sintered parts – make them ideal for a multitude of applications.
1) Tooling Industry: Perhaps the most prominent use case for RTP is in the tooling industry. Tungsten carbide tools are renowned for their hardness, strength, and wear resistance. Applications include end mills, drill bits, and other cutting tools used in metalworking and woodworking. The RTP allows these tools to be pressed into highly specific shapes and sizes, and sintered to achieve the requisite hardness and durability.
2) Automotive and Aerospace: In the automotive and aerospace sectors, RTP powders are utilized in the manufacture of high-performance engine components, such as pistons and valve seats, where high strength and wear resistance are necessary.
3) Oil and Gas: In the oil and gas industry, tungsten carbide components manufactured from RTP powders, such as drill bits and valves, are employed due to their ability to withstand the harsh, abrasive conditions encountered in drilling operations.
4) Medical Devices: The medical industry also uses RTP for the production of various medical devices and instruments. Tungsten carbide’s bio-compatibility makes it a suitable choice for surgical tools and implant components.
5) Electronics: In electronics, RTP powders are used in the manufacture of various electronic components and connectors that require high density, precision, and reliability.
6) Defense: In defense applications, RTP powders are used to produce various parts, such as armor-piercing projectiles, due to their high density and hardness.
These are just a handful of the wide-ranging applications of RTP powders. As you can see, the characteristics of these powders – their consistent quality, the precision they afford in manufacturing, and the durability and performance of the resulting components – make them highly versatile, and indeed indispensable, in the world of advanced manufacturing.
Top 7 Factors to Consider When Choosing Ready-to-Press Powder
1) Composition: The composition of the RTP powder is one of the primary considerations. This refers to the elemental makeup of the powder, which directly impacts the characteristics of the final product. Depending on your application, you might require a powder with a particular composition. For example, WC-Co (tungsten carbide-cobalt) is commonly used due to its exceptional hardness and toughness.
2) Grain Size and Distribution: The grain size and distribution also play an integral role in the properties of the final product. Smaller grains often result in a harder and more wear-resistant product, but may be more prone to grain growth during sintering. A uniform grain size distribution is usually desirable for predictable and uniform properties.
3) Binder Content: The binder, often cobalt, holds the tungsten carbide grains together. Different binder contents will yield different properties in the final product. Higher binder contents generally increase toughness but may decrease hardness and wear resistance.
4) Flowability: This refers to how well the powder flows, which is important for the pressing process. Good flowability will enable the powder to fill the die uniformly, resulting in a more consistent part.
5) Green Strength: The ‘green’ strength is the strength of the powder compact before it is sintered. Sufficient green strength is needed to handle the compact without it breaking or deforming.
6) Sintering Characteristics: Different RTP powders will behave differently during sintering. Factors such as shrinkage and porosity should be taken into account. Some powders may require special sintering conditions or treatments.
7) Supplier Reliability: Finally, consider the reliability and reputation of the supplier. They should provide consistent quality and be able to supply the quantities you require when you need them. It may be beneficial to work with a supplier who can provide technical support, especially if you are new to the powder metallurgy process.
The choice of RTP powder should always be guided by the requirements of the end application. Understanding these factors can help you make a more informed decision when purchasing RTP powders.
Top 6 Parameters to Consider for Application-Specific Selection of Ready-to-Press Powder
1) Hardness and Transverse Rupture Strength (TRS): Tungsten carbide’s hardness (HRA) and TRS are influenced by the percentage of cobalt (Co) binder. Typically, as Co content increases, hardness decreases but toughness (TRS) increases. Thus, for applications like cutting tools that require extreme hardness, you would want a lower Co %, like 6%. For applications that require more toughness to withstand impact, such as drilling tools, you’d prefer a higher Co %, like 12-15%.
2) Grain Size: The grain size of tungsten carbide can also affect hardness and toughness. Ultrafine and submicron grains provide high hardness but lower toughness, ideal for wear applications like cutting tools. Coarser grains increase toughness, suitable for impact-intensive applications like percussive drilling.
3) Porosity: During the sintering process, achieving the correct density is vital as it affects the mechanical properties. High density (low porosity) is desired for most applications, resulting in higher hardness and strength. Porosity in the material can be controlled by the pressing conditions and sintering parameters.
4) Corrosion Resistance: For applications that will be exposed to harsh conditions, including high temperature, chemical exposure, or wear, it’s important to consider the corrosion resistance of the material. Here, RTP powders with added corrosion-resistant components, such as chromium or nickel, can be beneficial.
5) Special Additives: For certain applications, special additives might be mixed with RTP. For instance, tantalum carbide or titanium carbide can increase the melting point and hardness of the final product, which is useful for high-speed cutting tools.
6) Cost-Performance Trade-off: High-performance RTP with low Co content, ultrafine grain size, or special additives tends to be more expensive. For cost-sensitive applications where extreme performance isn’t needed, a higher Co % or coarser grain size may be more appropriate.
These are general guidelines, and the exact specifications will depend on your specific application needs and production process. Always test different RTP formulations and optimize your process to achieve the desired properties.
Health, Safety, and Environmental Factors Related to Ready-to-Press Powder
RTP, like other powdered metallurgy materials, requires attention to several health and safety considerations due to its fine particle size and composition. First and foremost, because RTP is a fine powder, there is a potential for dust exposure during handling. Inhalation of tungsten carbide dust can cause harm to the respiratory tract. Thus, it’s important to utilize proper personal protective equipment (PPE), such as masks or respirators, and to ensure proper ventilation in the work area.
Tungsten carbide itself is generally considered non-toxic. However, RTP powders may contain cobalt as a binder, which can have toxic effects if inhaled or ingested in large amounts. Long-term exposure to cobalt dust can potentially lead to “hard metal lung disease,” a form of pneumoconiosis, so the same precautions to prevent dust inhalation should be taken seriously.
When it comes to skin contact, while RTP isn’t corrosive, the fine nature of the powder can lead to irritation due to mechanical action, so gloves should be worn during handling. Additionally, due to the powder’s fine size, there’s a potential risk of eye irritation or injury if it comes into contact with the eyes, making safety glasses or face shields a crucial part of PPE.
From an environmental standpoint, it’s essential to note that while tungsten is a naturally occurring element, it should not be indiscriminately released into the environment. Tungsten carbide powders should be recycled or disposed of properly in accordance with local and national regulations.
Finally, it’s worth noting that while not explosive, dust clouds of RTP, like many other fine powders, can pose a flammability risk if exposed to an ignition source under certain conditions. Hence, proper storage, handling, and dust control measures are critical in mitigating this risk.
While RTP is a highly beneficial material in the production of tungsten carbide parts, it’s important to handle it with the necessary safety precautions to protect human health and the environment. Awareness and adherence to these considerations are key in maintaining a safe and healthy workplace.
Looking Ahead: Top 7 Future Trends and Projections for Ready-to-Press Powder
1) Technical Innovation and New Use Cases: As technology continues to advance, we can expect the emergence of new applications and use cases for RTP. For example, the increasing focus on renewable energy sources may spur the development of more durable and efficient tools and components, further driving the demand for tungsten carbide parts.
2) Geopolitical Shifts in China: As the largest producer of tungsten in the world, changes in China’s tungsten production or export policies could significantly impact global RTP markets. If China were to restrict exports, it could potentially drive up prices and encourage exploration and production in other countries.
3) Geopolitical Shifts in USA: The United States is a major consumer of RTP for the production of tungsten carbide parts. Policies promoting domestic manufacturing could stimulate the demand for RTP. However, any environmental regulations affecting mining could potentially impact tungsten production and, consequently, RTP availability and price.
4) Geopolitical Shifts in Mexico: Mexico is emerging as a manufacturing hub, especially in the automotive and aerospace sectors, both of which make use of tungsten carbide parts. This growth could drive an increase in the demand for RTP in the region.
5) Decline of Coal Mining in North America: As North America continues to shift toward renewable energy sources, the demand for mining tools and equipment, including those made from tungsten carbide, may decline. This could impact the consumption of RTP-produced parts. However, these tools are also used in the extraction of other resources, potentially offsetting the decline.
6) Increasing Recycling Efforts: In response to environmental concerns, there may be an increased focus on recycling tungsten carbide parts, reducing the need for new RTP. This could influence RTP market dynamics and stimulate innovation in recycling technologies.
7) Advancements in Powder Metallurgy: As powder metallurgy techniques continue to evolve and improve, we might see more efficient use of RTP, leading to improved yields and reduced wastage.
These are just a few potential trends and projections in the world of RTP. It’s a rapidly changing field influenced by many factors, making it an exciting area of study for any aspiring engineer or metallurgist.
Top 4 Essential Tools for Transforming Ready-to-Press Powder
To transform Ready-to-Press (RTP) powder into final products, there are four main pieces of equipment you will need, each with its specific function. Let’s explore them:
1) Powder Compaction Press: This is where your RTP powder takes form. The powder is placed into a die of the desired shape, and a massive amount of force is applied to compress the powder into a solid “green” part. These presses can range from a few thousand dollars for a small manual press to a million dollars or more for a large, high-speed automatic press.
2) Sintering Furnace: After compaction, the green parts are taken to a sintering furnace. The furnace is heated to temperatures just below the melting point of the major constituent of the powder (in our case, tungsten carbide), allowing the particles to bond together. Sintering furnaces can range in cost from tens of thousands of dollars for a small batch furnace to several hundred thousand dollars for a larger, continuous furnace.
3) Debinding Equipment: Before sintering, the binder used in the RTP must be removed. This can be done either as a separate step using a debinding oven or solvent bath, or it can be combined with the sintering process in a single piece of equipment known as a debind-and-sinter furnace. The cost for debinding equipment can range from a few thousand to tens of thousands of dollars, depending on the capacity and technology.
4) Finishing Equipment: After sintering, the parts may require finishing operations to achieve the desired tolerances and surface finish. This can involve a variety of equipment, from simple hand tools for deburring, to CNC machines for precision machining, to polishing and coating equipment for final finishing. The costs for finishing equipment can vary widely depending on the complexity and precision required.
It’s important to remember that costs can vary widely based on the size, speed, and features of the equipment. In addition, keep in mind that this is a simplified overview; depending on the complexity of your operation and the products you’re making, you may need additional specialized equipment.
10 Key Considerations for Setting Up a Press-and-Sinter Facility
1) Facility Site Selection: The site chosen for the facility should be easily accessible and have enough space for installing the required equipment and machinery, storage for raw materials and finished products, as well as rooms for quality control, maintenance, and administrative tasks.
2) Space Requirements: You’ll need to have sufficient space for each of your operation stations – mixing, compacting, sintering, and post-processing (e.g., grinding, polishing). A larger facility may also need room for material testing and inspection areas. Don’t forget to allocate space for waste disposal and safety equipment.
3) Equipment Installation: Set up the necessary machinery as per the manufacturer’s instructions. This includes powder compaction presses, sintering furnaces, and potentially, grinding and polishing machines.
4) Utility Installation: Ensure the appropriate utilities (electricity, gas, water, HVAC) are installed and functioning. Furnaces will require a high-power supply, and your facility needs proper ventilation for safety.
5) Safety Considerations: Implement safety measures like proper ventilation, fire extinguishers, emergency exits, personal protective equipment, and material handling equipment. Train your personnel on safety procedures, emergency protocols, and correct handling of equipment and materials.
6) Quality Control and Inspection Area: Set up an area specifically for quality control, equipped with measurement tools like microscopes, hardness testers, density measurement tools, etc. Quality control is crucial in this industry.
7) Regulatory Compliances: Ensure your facility complies with all local and national regulations, including environmental, health, and safety rules. You may need to obtain permits before operation.
8) Hiring and Training: Staff your facility with skilled technicians and engineers. Provide training in operation and maintenance of the machinery, safety protocols, and quality control measures.
9) Trial Runs: Before starting full production, conduct trial runs to verify the functionality of all equipment and machinery and train the operators.
10) Continuous Improvement: Once your facility is operational, continue to monitor, evaluate, and improve your processes. Embrace lean manufacturing concepts and consider certifications such as ISO 9001.
By following this checklist, you can set up a successful press-and-sinter facility. Always remember, safety and quality control are paramount in this industry.
Top 8 Common Challenges in Press-and-Sinter Operations and their Solutions: A Troubleshooting Guide
1) Poor Compaction: Inadequate compaction may occur if the pressure is too low or the powder is not evenly distributed in the die. This issue can be resolved by adjusting the pressure settings and ensuring a uniform distribution of powder.
2) Die Wear: Prolonged usage of the die can cause wear, which could affect the quality of the parts produced. Regular inspection and maintenance, as well as prompt replacement of worn-out dies, can help overcome this problem.
3) Inconsistent Sintering: This problem often arises due to temperature variations in the sintering furnace. Ensuring a uniform temperature distribution in the furnace, along with maintaining the correct sintering time and temperature, can help in achieving consistent sintering.
4) Formation of Residual Stresses: These stresses could lead to deformation or cracking of the parts during cooling. Using a slow cooling rate and temperature control measures can help minimize the formation of residual stresses.
5) Improper Binder Removal: If the binder isn’t completely removed before sintering, it could cause defects such as porosity in the final product. Ensuring adequate debinding time and temperature can address this issue.
6) Poor Part Density: The final product may have a lower density than expected if the compacting pressure is too low or the sintering process isn’t optimized. Adjusting these parameters can improve part density.
7) Dimensional Inaccuracies: Parts might not meet the required dimensions due to die wear or thermal expansion during sintering. Regularly checking the dimensions of parts and adjusting the die dimensions or sintering parameters can help maintain dimensional accuracy.
8) Surface Defects: These can occur due to contamination of the powder or the die. Keeping the work environment clean and ensuring the powder is well-protected from contamination can help prevent surface defects.
Designing Cemented Carbide Parts for Press-and-Sinter
While the press-and-sinter process is largely reliable, these challenges can arise occasionally. It is important to monitor the process regularly and make adjustments as necessary to maintain the quality of the final cemented carbide parts.
1) Shrinkage Consideration: The shrinkage of carbide parts can vary, but on average, it’s around 18% linear shrinkage, which translates to approximately 50% volume reduction. This shrinkage is not always uniform and can vary depending on the part geometry and the distribution of different powder constituents. Therefore, it’s crucial to account for the shrinkage factor in your CAD design. There are also sintering simulation software tools that can help predict and compensate for the shrinkage.
2) Design Complexity: While the press-and-sinter process can produce complex shapes, designs with overhanging features, intricate internal channels, or extreme aspect ratios can be problematic. It’s essential to balance complexity with manufacturability, ensuring the parts can be ejected from the mold without causing deformations or fractures.
3) Uniform Wall Thickness: Aim to maintain a uniform wall thickness in your design wherever possible. Parts with varying thickness can have issues such as differential shrinkage, leading to warping or even cracking. If different thicknesses are necessary, try to transition gradually rather than abruptly.
4) Tolerances: In general, tolerances of +/- 0.5% of the dimension are achievable with press-and-sinter. However, if your design requires tighter tolerances, you might need to consider secondary machining operations post-sintering or using advanced pressing techniques such as hot isostatic pressing (HIP).
5) Undercuts: Undercuts can cause parts to become stuck in the die during ejection. If undercuts are necessary in your design, consider using a multi-part die system or a die with movable parts that can accommodate these features.
6) Draft Angles: Draft angles of about 1-3 degrees are typically sufficient to facilitate the ejection of the part from the die. Keep in mind that the need for draft angles can be reduced with the use of modern lubricants and improved die materials.
7) Part Size: Larger parts require a higher pressing force, which can lead to more significant density gradients within the part. Consider using a process like cold isostatic pressing (CIP) for larger parts, which applies pressure uniformly from all directions, reducing density variations.
8) Simulation Software: Make use of software tools like finite element analysis (FEA) for simulating the sintering process. This can help to optimize your design by predicting potential issues like internal stresses, deformation, or cracking, and it allows you to visualize the shrinkage and deformation that could occur during sintering.
By taking these detailed considerations into account, you can optimize your design for the press-and-sinter process and mitigate potential challenges that could arise during manufacturing.
7 Key Strategies for Successfully Marketing Your Cemented Carbide Parts
1) Specialized Applications: When marketing your carbide parts, emphasize the specific applications that benefit most from cemented carbide’s unique properties. For example, high-wear applications such as mining or drilling, where hardness, toughness, and resistance to extreme conditions are paramount.
2) Innovation and Customization: The carbide industry thrives on innovation. Highlight your ability to customize and create unique carbide formulations for specific industry needs. For instance, the development of gradient sintered carbide has allowed for parts with varying properties throughout, which can be a key selling point for certain applications.
3) Emphasize Longevity: Cemented carbide parts, while more expensive than their steel or iron counterparts, tend to last much longer. Make sure your potential customers understand that, in the long run, they’ll save money by reducing their replacement costs.
4) Eco-friendly Initiatives: Carbide recycling is a growing trend due to the high cost of tungsten. If you are implementing recycling measures in your production process, this can be a significant selling point to environmentally conscious customers.
5) Rapid Turnaround and Prototype Development: In many industries, speed is key. If you have the capacity to rapidly produce prototypes or rush orders, this could provide a significant competitive advantage.
6) Technical Support: In such a technical field, having experts on hand to advise and consult with customers is a significant selling point. Engineers and technicians should be readily available to work with customers on their specific needs and challenges.
7) Quality Assurance Specific to Carbide Production: Emphasize rigorous quality assurance processes that are specific to carbide production, such as ensuring minimal porosity, homogeneous microstructure, and the right balance of hardness and toughness.