Producing fully dense PM parts

A new process from PM Krupp Technologies Inc., F2, is suitable for producing fully dense parts that are too expensive to machine or cast, or that require the high strength, hardness, and durability that conventional (low-density) powder metal cannot provide.

The great value of low-cost, high-production, near-net-shape powder-metal components has never reached its full potential because of insufficient product density. Conventional powder-metallurgy components-marked by 6.8-7.0 g/cm³ (3.9-4.1 oz/in³) densities-have lacked the high strength and hardness necessary for many industrial applications. This is particularly true in the automotive sector. Lack of product density, and therefore lack of strength and hardness, has forced manufacturers that require higher mechanical properties to use more expensive metalworking techniques (e.g., casting, forging, and machining).

The powder-metal industry has been working on the density problem for years with the goal to achieve near-full density or components with <1% residual porosity. Limited successes (not 100% density) have been achieved with processes such as cold isostatic pressing, metal-injection molding, spray forming, and powder forging.