Co-based amorphous powder was produced by a new atomization process “Spinning Water Atomization Process (SWAP)”, having rapid super-cooling rate. The composition of the alloys was ((Co0.95Fe0.05)1-xCrx)75Si15B10 (x=0, 0.025, 0.05, 0.075). The powders became the amorphous state even if particle size was up to about 500 μm. The coercive force of powders was about 0.35 - 0.7 Oe. Furthermore, Co-based amorphous powder cores with glass binders were made by cold-pressing and sintering methods. The initial permeability of the core in the frequency range up to 100 kHz was about 110, and the core loss at 100 kHz for Bm = 0.1 T was 350 kW/m3.

The powder forging (PF) process is used to produce fully dense powder metallurgy (PM) parts for high performance automotive applications. PF connecting rods have been widely accepted in the US, Japan, and other countries due to higher performance and lower manufacturing costs when compared to conventionally forged steel connecting rods [1]. In order to meet and exceed requirements for higher fatigue strength and better machinability of PF connecting rods, a newly developed machinability enhancer, named KSX, was introduced [2]. A comparison study between powder forged materials prepared with 0.3% MnS and with 0.1% KSX additions showed excellent properties in the case of the mix with KSX.

Gas surface treatment is considered to be effective for titanium because of its high reactivity. In this study, we investigated the gas nitriding mechanism in titanium sintered parts produced by metal powder injection molding (MIM) process. The microstructure and nitrogen content of sintered MIM parts were greatly affected by nitriding conditions. Nitriding process strongly depended on the specimen size, for example, the size of micro metal injection molding (μ-MIM) product is so small and the specific surface is so large that the mechanical and functional properties can be modified by nitriding.

The MIM industry is currently focusing on parts that are used in automobiles and medical instruments. Many of the parts in these categories are very small and often not easy to machine because of its complex geometry. Therefore MIM is well suited for the production of these parts. We tested the sinterability of SUS316L ultra fine powders (3,4, 6, 8micron) produced by ATMIX high-pressure water-atomization, and it showed excellent results. A density of 97% theoretical was obtained by sintering at 1373K when using the ultra fine powder (3micron). Specifically, the finer the powder size, higher was the sintered density. The surface roughness and accuracy are also greatly improved with ATMIX ultra fine powder.

Ceramic Injection Moulding (CIM) technology has been successfully used for the fabrication of Mn-Zn Ferrite part. The binder was composed by polypropylene and paraffin wax. The optimal powder loading (58% vol.) was determined by means of rheological measurements. Threedifferent parts, toroids, bending and tensile probes were injected. Thermal and solvent-thermal debinding was designed based on DSC and TGA studies of the binder. The time of the debinding cycle was reduced using n-heptane to dissolve previously the paraffin wax. Final properties have been determined and compared with uniaxial pressure parts values. The densities obtained were slightly higher than those of uniaxial pressure parts and the magnetic properties presented similar values.

W-Cu alloy was very useful material for a heat sink, high electric contact and EDM electrode. Powder injection molding (PIM) is the optimum manufacturing technology to provide W-Cu components with low-cost and high-volume. We used various compositions of tungsten coated copper powders (W-Cu with 10 to 80 wt-% of copper) to manufacture W-Cu components by PIM. The optimum mixing, injection molding, debinding and sintering conditions to provide the high performance W-Cu components were investigated. The thermal and mechanical properties of W-Cu parts by PIM were measured. Finally, we can verify the high performance of W-Cu components by PIM with the tungsten coated copper.

We investigated the mechanism how the high green density can be provided during die lubricated warm compaction (WD). We observed and analyzed the densification processes of iron powders including different contents of an inner lubricant, and measured the lateral pressure at the die wall during WD in comparison with conventional compaction and warm compaction. As a result, the high density in WD was due to not only the particles-deformation enhanced by warming powders but also the particles-rearrangement promoted by reducing an amount of the inner lubricant rather than the die lubrication.

Filling of the tool die directly influences dimensional tolerances and density variation. To minimize the variations in filling, both within different sections of the cavity and from part to part, are of great importance for produce high quality P/M parts. Filling of the tool die is also one of the limiting factors in the productivity in powder pressing. By using aeration filling in combination with bonded powder mixes, both weight scatter and productivity can be improved. In this presentation results are presented showing the benefit of using aeration filling for different types of powders

The achievement of high density at reasonable cost is one of the major challenges of the P/M industry. One of the key factors contributing to the compressibility of a mix is the lubricant. New experimental lubricants enabling higher green density by conventional compaction or temperature-controlled die compaction were identified. The compaction and ejection characteristics of these new lubricants as measured with a fully instrumented lab press are presented and compared to that of conventional lubricants.

Organically bonded P/M mixes have been developed to improve the stability of dimensional properties by reducing the segregation of the mix constituents and improving the filling characteristics. Robustness and reliability are key factors for the promotion of P/M as cost effective substitute of competing manufacturing technologies. Based on the production of four different belt pulleys, this paper presents the achievement of reduced weight scatter and close dimensional control realizable by using a StarmixTM that is organically bonded.

Granulated powders, prepared from PF-5F(D50=4μm), PF-10F(D50=6μm) and PF-20F(D50=10μm) water atomized powder, were compacted, debound and sintered to evaluate the properties of sintered parts. As a result, the relative sintered density of about 97% at sintering temperature of 1423K was obtained. It can be considered that by using granulated finer particle size powder, mechanical properties of sintered parts were also improved.

Recently warm compaction techniques are focused on and commercialization of one high-density compaction process in the P/M industry. Another development is a new SEGLESS using a developed lubricant that reduces ejection force at room temperature compaction. It is possible to achieve high-density by reducing lubricant amount. In this paper we confirmed that green density was 7.35 g/cm3 at 686MPa of compaction pressure when the new SEGLESS was applied to relatively lower temperature warm compaction process, such as 80℃.

Discrete element analysis is used to map various log-normal particle size distributions into measures of the in-sphere pore size distribution. Combinations evaluated range from monosized spheres to include bimodal mixtures and various log-normal distributions. The latter proves most useful in providing a mapping of one distribution into the other (knowing the particle size distribution we want to predict the pore size distribution). Such metrics show predictions where the presence of large pores is anticipated that need to be avoided to ensure high sintered properties.

The particle size distribution and shape are among the important parameters for characterisation of quality of metal powders. Specific material properties such as ability to flow, reactivity as well as compressibility and its hardening potentials hence the most important characteristics of sintered metals - are determined by the size distribution and shape. The correct particle size distribution and particle shape information are the key to best product quality in atomisation processes of aluminium, milling of pure metals and other processes. This paper presents state-of-the-art technology for characterization of particle size distribution and shape.

Spherical Ag powder was prepared in the system of by wet chemical reduction method. The size of Ag powder was increased as the reaction temperature and the concentration of reducing agent was decreased in the constant concentration of dispersion agent. Optimum conditions of producing Ag powder having of D50 was 1M of , 0.5M of , 1.5g of Gelatine in the room temperature.

The amorphous alloy strip was pulverized to get a flake-shaped powder after annealing at for 90 min and subsequently ground to obtain finer flake-shaped powder by using a ball mill. The powder was mixed with polyimide-based binder of , and then the mixture was cold compacted to make a toroidal powder core. After crystallization treatment for 1 hour at , the powder was transformed from amorphous to nanocrystalline with the grain size of . Soft magnetic characteristics of the powder core was optimized at with the insulating binder of 3wt%. As a result, the powder core showed the outstanding magnetic properties in terms of core loss and permeability, which were originated from the optimization of the grain size and distribution of the insulating binder.

최근 미국 ANL연구소가 개발한 다이포실 수지는 우라늄의 선택특성이 우수하나 수지의 형태가 분말형이므로 입상의 비드형으로 제조하기 위하여 다이포실 분말을 알기네이트상에 고정화하는 방법을 적용하였다. 생성된 비드의 우라늄에 대한 흡착특성을 측정한 결과, 소디움 알기네이트 자체도 우라늄 흡착특성을 최대 68%까지 나타낸 후 30% 수준으로 감소하였으며, 이는 흡착후 탈착하는 과정을 거쳐 평형에 이르는 것으로 사료된다. 또한 비드내 다이포실의 양이 증가할수록 우라늄의 흡착이 증가하며 최대 85 %정도의 흡착율을 나타내고 있다. 다이포실 수지만의 경우 반응초기에 급격한 흡착을 보이고 있으나 3일정도 이후에는 비드의 흡착율과 유사한 결과를 나타내고 있으며 비드내 함유된 순 다이포실량을 고려할 경우 알기네이트 자체의 흡착효과로 인해 비드의 흡착효율이 크게 상승되는 것으로 해석된다. 우라늄 농도의 영향은 농도의 증가에 따라 우라늄의 제거효율이 감소하였으며, 비드의 양을 2배로 증가시킨 결과 최대 90%이상의 제거효율을 얻었다. 결론적으로 다이포실 수지를 소디움 알기네이트상에 고정화하여 입자형의 비드로 제조하므로서 적은 양의 수지로 우라늄 제거특성이 우수한 비드를 얻을 수 있었으며 나아가서 연속공정에의 적용도 가능한 것으로 사료된다.