Metal Powder Production Powder Production: Shape Particle size Size distribution
Depends on powder production method Production of Iron Powders
Powder Production
Water-atomisation process Majorly used process. ( Plain powders , low alloy powders , stainless steels and tool steels)
Sponge iron process Solid state reduction of iron ore ( Majorly Fe3O4)
Alloying methods - Premix , organic bonded mix. Brazil Belgium India Japan China United Kingdom Sweden Hgans Sweden Halmstad North America Stony Creek North America Niagara Falls North America SCM Johnstown Production Centres Sponge iron - Hgans Atomisation -Halmstad -Stony Creek -India -Brazil High Alloy -Belgium -SCM Johnstown -United Kingdom Powder production in Sweden Halmstad Atomising plant Hgans Sponge Iron plant Powder plant Distaloy plant Astaloy plant Customer mixes
Iron powders Examples: ASC100.29 ABC100.30 AHC100.29 Examples: NC100.24 SC100.26 MH80.23 AHC 100.29 Mesh Size Apparent density (g/cc) Water-atomising process
A. Tundish B. Steel stream C. High pressure water D. Nozzle E. Atomised iron powder Variables in Atomization Process: Superheat degree of molten metal. Angle of injection of water Nozzle size. Metal to water ratio Water pressure. Water-atomising process
1. Selected scrap 2. Arc furnace 3. Liquid steel 4. Injection 5. Atomising 6. Dewatering 7. Drying 8. Magnetic separation 9. Screening 10. Equalising 11. Transportation to Hgans h pressure water Atomised iron powders Examples: ASC100.29 ABC100.30 AHC100.29 Sponge iron process 1. Reduction mix of coke breeze and limestone 2. Iron ore 3. Drying 4. Crushing 5. Screening 6. Magnetic separation 7. Charging in ceramic tubes 8. Reduction in tunnel kilns, approximately 1200C 9. Discharging 10. Coarse crushing 11. Storage in silos 12. Crushing 13. Magnetic separation 14. Grinding and screening 15. Annealing in belt furnace, 800-900C 16. Equalising 17. Automatic packing 18. Iron ore 19. Reduction mix 20. Control room Sponge iron process 1. Reduction mix of coke breeze and limestone 2. Iron ore 3. Drying 4. Crushing 5. Screening 6. Magnetic separation 7. Charging in ceramic tubes 8. Reduction in tunnel kilns, approximately 1200C 9. Sponge iron process 1. Reduction mix of coke breeze and limestone 2. Iron 7. Charging in ceramic tubes 8. belt furnace, 800-900C. Automatic packing 18. Iron ore 19. Reduction mix 20. Control room Sponge iron process 1. Reduction mix of coke breeze and limestone 2. Iron ore 3. Drying 4in ceramic tubes 8. Reduction in tunnel kilns, approximately 1200C 9. Discharging Sponge iron process 1. Reduction mix of coke breeze and limestone 2. Iron ore 3. Drying 10. Coarse crushing 11. Storage in silos 12. Crushing 13. Magnetic separation 14. Grinding and screening 15. Annealing in belt furnace, 800-900C 16. Equalising 17. Automatic packing 18. Iron ore 19. Reduction mix 20. Control room Sponge iron process 1. Reduction mix of coke breeze and limestone 2. Iron ore 3. Drying 4and screening 15. Annealing in belt furnace, 800-900C 16. Equalising 17. Automatic packing Sponge iron powders Examples: NC100.24 SC100.26 MH80.23 Sponge Vs Atomized iron Powders Mahesh Nipanikar 19 | Compressibility 5.6 5.8 6.0 6.2 6.4 6.6 6.8 7.0 7.2 7.4 7.6 200 300 400 500 600 700 800 900 Compating pressure (MPa) G r e e n
d e n s i t y
( g / c m 3 ) ABC100.30 ASC100.29 AHC100.29 SC100.26 NC100.24 MH80.23 Lubricated die Sponge Vs Atomized iron Powders Green strength 5 10 15 20 25 30 35 40 200 300 400 500 600 700 800 900 Compating pressure (MPa) G r e e n
s t r e n g t h
( M P a ) MH80.23 NC100.24 SC100.26 ABC100.30 ASC100.29 AHC100.29 0.6% Kenolube Alloying methods PRE-ALLOYED ASTALOY DIFFUSION ALLOYED DISTALOY PRE-MIXED ORGANIC BONDED STARMIX Alloying methods Pre-alloyed Atomization Advantages: No segregation of alloying elements Homogeneous microstructure Disadvantages: Hard to make alloying changes Pre-alloyed powders- Astaloys Powder grade Alloying elements Properties Astaloy Mo 1,5% Mo High compressibility with optimal hardenability--> surface hardened components Astaloy A 1,9% Ni, 0,5% Mo, 0,25% Mn Primarily for powder forging Good hardenability Astaloy 85 Mo 0,85% Mo Advantages as Astaloy Mo, but less hardenability Astaloy CrM 3% Cr, 0,5% Mo Excellent hardenability, high strength and hardness after sintering Alloying methods - Diffusion alloyed Advantages: Higher compressibility than a pre-alloyed with same composition Low segregation of alloying elements Disadvantages: Fixed composition + Sponge powder Atomised powder Cu, Ni, Mo Cu, Ni, Mo + Mixing Diffusion alloyed powders Powder grade Base powder Alloying elements Properties Distaloy SA SC100.26 1.75% Ni, 1.5% Cu and 0.5% Mo High green strength Distaloy AB ASC100.29 " High compressibility Distaloy SE SC100.26 4% Ni, 1.5% Cu and 0.5% Mo High green strength Distaloy AE ASC100.29 " High compressibility Distaloy DC-1 (Dimensional control) Astaloy Mo 2.1% Ni (and 1.5% Mo) No DC change with density Distaloy DH-1 (Direct hardening) Astaloy Mo 2% Cu (and 1.5% Mo) High hardenability Distaloy HP-1 (High performance) Astaloy Mo 4% Ni, 2% Cu (and 1.5% Mo) Highest mechanical properties Compressibility Chemical composition 1,75 % Ni 1,5 % Cu 0,5 % Mo Alloying methods PRE-MIXED ORGANIC BONDED STARMIX Easy to change composition Segregation Product consistency Better flow compared to Premix Low dusting Close to 100% bonding of graphite Alloying methods PRE-MIXED ORGANIC BONDED STARMIX 0,15 0,20 0,25 0,30 0,35 0,20 0,30 0,40 0,50 Carbon content D i m e n s i o n a l
c h a n g e 0,15 0,20 0,25 0,30 0,35 0,20 0,30 0,40 0,50 Carbon content D i m e n s i o n a l