US2003047032A1PendingUtilityA1

Method of producing powder metal parts from metallurgical powders including sponge iron

38
Priority: Jun 22, 2001Filed: Jun 22, 2001Published: Mar 13, 2003
Est. expiryJun 22, 2021(expired)· nominal 20-yr term from priority
Inventors:Keith NewmanJohn C. Kosco
B22F 2999/00C22C 33/02C22C 33/0207
38
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

A method of forming a part from a metallurgical powder, comprises compressing at least a portion of a metallurgical powder, including sponge iron to provide a green compact. The green compact is subsequently sintered to provide a sintered compact.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A method of forming a powder metal material, the method comprising: 
 compressing at least a portion of an iron-containing metallurgical powder in a die at no greater than 20 tsi to provide a green compact, wherein the metallurgical powder comprises sponge iron; and    sintering the compact.    
     
     
         2 . The method of  claim 1 , wherein the sponge iron includes substantially all of the iron in the metallurgical powder.  
     
     
         3 . The method of  claim 1 , wherein the metallurgical powder comprises at least 10 up to 50 weight percent sponge iron.  
     
     
         4 . The method of  claim 1 , wherein the metallurgical powder further comprises at least one of a pure atomized iron powder and an atomized iron-containing powder.  
     
     
         5 . The method of any of claims  1  and  4 , wherein sintering the green compact comprises induction sintering the green compact.  
     
     
         6 . The method of  claim 1 , wherein the metallurgical powder further comprises no more than 0.3 weight percent of internal lubricant.  
     
     
         7 . The method of  claim 1 , wherein compressing at least a portion of the metallurgical powder comprises compressing at least a portion of the metallurgical powder in a self-lubricating die.  
     
     
         8 . The method of  claim 1 , wherein compressing the metallurgical powder comprises compressing the metallurgical powder at a pressure in the range of 5 tsi up to 20 tsi.  
     
     
         9 . The method of  claim 1 , wherein the green compact has a green strength of at least 1000 psi.  
     
     
         10 . The method of  claim 1 , wherein the green compact has a density of at least 4.0 g/cc.  
     
     
         11 . The method of  claim 1 , further comprising: 
 hot forming the sintered compact.    
     
     
         12 . The method of  claim 1 , wherein the metallurgical powder optionally includes at least one of: 
 up to 3 weight percent graphite;    up to 12 weight percent nickel;    up to 3 weight percent molybdenum;    up to 10 weight percent copper;    up to 2 weight percent manganese;    up to 20 weight percent chromium; and    up to 0.3 weight percent internal lubricant.    
     
     
         13 . A method of forming a powder metal material, the method comprising: 
 compressing at least a portion of an iron-containing metallurgical powder in a die to provide a green compact, wherein the metallurgical powder comprises sponge iron and at least one of an atomized iron powder and an atomized iron-containing powder;    sintering the compact.    
     
     
         14 . The method of  claim 13 , wherein the metallurgical powder comprises at least 10 up to 50 weight percent of the sponge iron.  
     
     
         15 . The method of any of  claim 13 , wherein sintering the green compact comprises induction sintering the green compact.  
     
     
         16 . The method of  claim 13 , wherein the metallurgical powder further comprises up to about 0.3 weight percent of internal lubricant.  
     
     
         17 . The method of  claim 13 , wherein compressing at least a portion of the metallurgical powder comprises compressing at least a portion of the metallurgical powder in a self-lubricating die.  
     
     
         18 . The method of  claim 13 , wherein compressing the metallurgical powder comprises compressing the metallurgical powder at a pressure no greater than 20 tsi.  
     
     
         19 . The method of  claim 13 , wherein the green compact has a green strength of at least 1000 psi.  
     
     
         20 . The method of  claim 13 , wherein the green compact has a density of at least 4.0 g/cc.  
     
     
         21 . The method of  claim 1 , further comprising: 
 hot forming the sintered compact.    
     
     
         22 . A powder metal material formed by a method comprising: 
 compressing at least a portion of an iron-containing metallurgical powder in a die at no greater than 20 tsi to provide a green compact, wherein the metallurgical powder comprises sponge iron; and    sintering the compact.    
     
     
         23 . The powder metal material of  claim 22 , wherein the sponge iron includes substantially all of the iron in the metallurgical powder.  
     
     
         24 . The powder metal material of  claim 22 , wherein the metallurgical powder comprises at least 10 up to 50 weight percent of the sponge iron.  
     
     
         25 . The powder metal material of  claim 22 , wherein the metallurgical powder further comprises at least one of a pure atomized iron powder and an atomized iron-containing powder.  
     
     
         26 . The powder metal material of  claim 22 , wherein sintering the green compact comprises induction sintering the green compact.  
     
     
         27 . The powder metal material of  claim 22 , wherein the metallurgical powder further comprises no more than 0.3 weight percent of internal lubricant.  
     
     
         28 . The powder metal material of  claim 22 , wherein compressing at least a portion of the metallurgical powder comprises compressing at least a portion of the metallurgical powder in a self-lubricating die.  
     
     
         29 . The powder metal material of  claim 22 , wherein compressing the metallurgical powder comprises compressing the metallurgical powder at a pressure in the range of 5 tsi up to 20 tsi.  
     
     
         30 . The powder metal material of  claim 22 , wherein the green compact has a green strength of at least 1000 psi.  
     
     
         31 . The powder metal material of  claim 22 , further comprising: 
 hot forming the sintered compact.    
     
     
         32 . A powder metal material formed by a method comprising: 
 compressing at least a portion of an iron-containing metallurgical powder in a die to provide a green compact, wherein the metallurgical powder comprises sponge iron and at least one of an atomized iron powder and an atomized iron-containing; and    sintering the compact.    
     
     
         33 . The powder metal material of  claim 32 , wherein the sponge iron includes substantially all of the iron in the metallurgical powder.  
     
     
         34 . The powder metal material of  claim 32 , wherein the metallurgical powder comprises at least 10 up to 50 weight percent of the sponge iron.  
     
     
         35 . The powder metal material of  claim 32 , wherein the metallurgical powder further comprises at least one of a pure atomized iron powder and an atomized iron-containing powder.  
     
     
         36 . The powder metal material of  claim 32 , wherein sintering the green compact comprises induction sintering the green compact.  
     
     
         37 . The powder metal material of  claim 32 , wherein the metallurgical powder further comprises no more than 0.3 weight percent of internal lubricant.  
     
     
         38 . The powder metal material of  claim 32 , wherein compressing at least a portion of the metallurgical powder comprises compressing at least a portion of the metallurgical powder in a self-lubricating die.  
     
     
         39 . The powder metal material of  claim 32 , wherein compressing the metallurgical powder comprises compressing the metallurgical powder at a pressure in the range of 5 tsi up to 20 tsi.  
     
     
         40 . The powder metal material of  claim 32 , wherein the green compact has a green strength of at least 1000 psi.  
     
     
         41 . The powder metal material of  claim 32 , further comprising: 
 hot forming the sintered compact.    
     
     
         42 . An article of manufacture comprising the material of any of claims  22  and  32 .  
     
     
         43 . The article of manufacture of  claim 42 , wherein the article is one of a bearing, a cam, a gear, and a sprocket.

Join the waitlist — get patent alerts

Track US2003047032A1 — get alerts on status changes and closely related new filings.

We store only your email — no account needed. See our privacy policy.