Papers by Author: K.S. Hwang

Abstract: High strength and high hardness can be readily attained after sintering when sinter-hardening grade powder metallurgy alloys are used. However, fast cooling rates greater than 60°C/min are usually required. This increases the cost of the sintering equipment and maintenance. To lower the required minimum cooling rate, the homogeneity of the alloying elements in the matrix and the hardenability of the material must be improved. Among the various popular alloying elements, nickel and carbon are the two most non-uniformly distributed elements due to their repelling effect. It is found that to improve their homogenization, the addition of Cr and Mo can alleviate the repelling effect between Ni and C. As a result, weak Ni-rich/C-lean ferrite and austenite are eliminated and replaced by hard bainite and martensite. A tensile strength of 1323 MPa and a hardness of 39 HRC are attained in sinter-hardened Fe-3Cr-0.5Mo-4Ni-0.5C compacts without any quenching treatment.

Abstract: Homogeneous microstructures of the PM compacts are difficult to attain when mixed elemental powders are used. This study examined the microstructures of pressed-and-sintered and MIM products that contain Ni and Mo. Ni-rich areas, which were lean in carbon and were soft, were found easily in regular specimens. Gaps or cracks near the Ni-rich or Mo-rich areas were also frequently observed. This problem got worse when Ni and Mo particles were large and were irregular in shape. By using ball milling treatment and ferroalloy powders, the microstructure homogeneity and mechanical properties were improved. The addition of 0.5wt%Cr further improved the distribution of Ni because Cr reduced the repulsion effect between nickel and carbon. With the elimination of Ni-rich areas, more bainites and martensites were formed and mechanical properties were significantly improved.