Papers by Author: João M.G. Mascarenhas

Abstract: The present paper focus on preliminary work carried out at INETI concerning the use of microwave radiation applied to sintering of both ceramic and metal powders. Due to the characteristics of materials-radiation interaction, microwaves can become an interesting power source in powder technology and other processing routes, since it is possible to lower the sintering temperature and shorten the sintering cycles, leading to time and energy savings. Alumina, hydroxyapatite, titanium and stainless steel powder compacts were sintered in a modified commercial oven of 2.45GHz and 1000W nominal power. Microwave susceptors were used to enable temperature rise during the initial stage of the sintering cycles. Results on densification and microstructural evaluation of microwave sintered samples are reported and compared to conventionally sintered ones, when available. For similar porosity levels upon sintering, microwave radiation generally reduces sintering times from several hours to minutes. The results obtained so far are quite encouraging since in the case of alumina and stainless steel compacts, a decrease of about 200°C in the sintering temperature was achieved. It was also found that the green density plays a key role in the densification of both metallic and ceramic powders.

Abstract: The present study aims to prepare feedstocks for MIM (Metal Injection Molding) where the metal powders are 316L stainless steel powders (SS). The master objective is to compare the performance of a biodegradable binder with a commercial one based on polyolefins. Different challenges must be overcome in SS injection molding, as follows: to decrease binder/carbon content in feedstocks; to decrease carbon contamination during debinding and sintering; to avoid the formation of chromium carbide and presence of precipitation-free zones; to avoid the grain growth during sintering and to reduce the feedstock price. The optimization of the feedstocks was performed using a torque rheometry technique. Feedstocks of coated and uncoated SS powders mixed with an agar-based binder were used to produce sound parts. A feedstock constituted by SS powders mixed with a high quality commercial binder was the standard. SS with agar-based on feedstocks can admit solids content similar to those based on the commercial binder (62 vol.%). For similar powder content, the sinters resulting from feedstocks with the agar-based binder shows a lower quantity of solid solution of carbon and chromium carbides, absence of precipitation-free zones than commercial feedstocks and good sinter soundness. Coating powders with nanocrystalline stainless steel contribute to control grain growth during debinding and sintering.

Abstract: This paper presents the results of an investigation into the sintering behaviour of three vanadium enriched variants of T42 high-speed steel. Powders were prepared by water atomization with vanadium and carbon contents of 6-8 wt% and 2.2 -2.7 wt%, respectively. These were annealed, die pressed and sintered in vacuum. All three alloys were sintered to full density giving “as –sintered” microstructures comprising globular MC carbides dispersed in a martensitic matrix. Optimum sintering temperatures were in the range 1240 - 1250°C with lower optimum temperatures associated with higher carbon levels. Sintering characteristics are correlated with phase diagrams calculated using ThermoCalc™ software and TCFe2000 database. The implications for the design of sinterable vanadium containing high-speed steels are discussed.