Abstract: Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.

Abstract: Metallurgical powder compositions of the present invention include an iron based powder combined with a master alloy powder, as a mechanical property enhancing powder. The addition of master alloy powders has been found to enhance the mechanical properties of the final, sintered, compacted parts made from metallurgical powder compositions, especially at low sintering temperatures. Metallurgical powder compositions include at least about 80 weight percent of an iron-based metallurgical powder and from about 0.10 to about 20 weight percent of a master alloy powder. Master alloy powders include iron and from about 1.0 to about 40 weight percent chromium, and from about 1.0 to about 35 weight percent silicon, based on the weight of the master alloy powder.

Abstract: Metallurgical powder compositions of the present invention include an iron based powder combined with a master alloy powder, as a mechanical property enhancing powder. The addition of master alloy powders has been found to enhance the mechanical properties of the final, sintered, compacted parts made from metallurgical powder compositions, especially at low sintering temperatures. Metallurgical powder compositions include at least about 80 weight percent of an iron-based metallurgical powder and from about 0.10 to about 20 weight percent of a master alloy powder. Master alloy powders include iron and from about 1.0 to about 40 weight percent chromium, and from about 1.0 to about 35 weight percent silicon, based on the weight of the master alloy powder.

Abstract: Provided are corrosion resistant metallurgical powder compositions, corrosion resistant compacted articles prepared from metallurgical powder compositions, and methods of preparing the same. Corrosion resistant metallurgical powder compositions include as a major component, an iron-based powder and, as a minor component, alloy additives that include chromium, and carbon. Upon compaction and sintering, the iron-based powder and alloy additives form a dual phase alloy system. The dual phase alloy system is denoted by an admixed martensite and ferrite microstructure. This unique microstructure results in beneficial physical properties, such as for example, high strength, hardness, and ductility, impact energy, and fatigue endurance, while maintaining resistance to corrosion.

Abstract: The present invention relates to improved metallurgical powder compositions that incorporate solid lubricants, methods for preparing and using the same, and methods of making compacted parts. The solid lubricants contain functionalized polyalkylene lubricants substituted with functional groups selected from the group consisting of a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group.

Abstract: The present invention relates to improved metallurgical powder compositions that incorporate solid lubricants, methods for preparing and using the same, and methods of making compacted parts. Ejection properties, such as stripping pressure and sliding pressure, of compacted parts can be improved by using the solid lubricants. The solid lubricants contain functionalized polyalkylene glycol lubricants that contain a phosphate group, phosphite group, hypophosphate group, hypophosphite group, polyphosphate group, thiophosphate group, dithiophosphate group, thiocarbamate group, dithiocarbamate group, borate group, thiosulfate group, sulfate group, a sulfonate group or combinations thereof.

Abstract: Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based powder, that constitutes the major portion of the composition. A silicon carbide-containing powder is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a “green” compact that is then sintered, preferably at relatively high temperatures.

Abstract: The present invention relates to improved metallurgical powder compositions that incorporate solid lubricants, methods for preparing and using the same, and methods of making compacted parts. Ejection properties, such as stripping pressure and sliding pressure, of compacted parts can be improved by using the solid lubricants. The solid lubricants contain functionalized polyalkylene lubricants have the formula: R1—Q—R2 where Q is a linear or branched, polyalkylene containing from about 10 to about 200 carbon atoms, and R1 and R2 are each independently a hydroxyl group, a carboxylic acid group or a metal salt thereof, an amine group, a mono- or di-C1 to C25 alkyl substituted amine group, or an alkylene oxide group having the formula: —[(CH2)qO]nH where q is from about 1 to about 7, n is from about 1 to about 100.

Abstract: Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based powder, that constitutes the major portion of the composition. A silicon carbide-containing powder is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a “green” compact that is then sintered, preferably at relatively high temperatures.

Abstract: Methods of making and using annealable insulated metal-based powder particles are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.

Abstract: Improved methods for coating particulate materials at low shear conditions and preferably below the melting point of the coating material are provided. In one aspect, metallurgical compositions are provided that contain a metal-based powder bound to an alloying powder or powders by way of a low melting polymer or wax binding agent, which is preferably polyethylene. The binding agent is blended with the metal-based and alloying powders at elevated temperatures preferably below the melting point of the binding agent. The bonded metallurgical composition can be used in compaction processes to manufacture compacted parts that can be sintered to impart strength.

Abstract: A method is provided for compacting metal-based powder compositions containing at least one thermoplastic material at temperatures below the glass transition temperature or melting temperature of the thermoplastic material to form a metal-based component. Preferably, compaction is carried out at temperatures ranging from ambient to about 55° C. The method of the present invention is particularly useful for making magnetic core components. The present invention also provides metal-based powder compositions useful for cold compaction. The metal based powder compositions contain metal-based particles containing no iron phosphate layer; a thermoplastic material selected from polyetherimides, polyphenylene ethers, polyethersulfones, polycarbonates, polyethylene glycol, polyvinyl acetate, polyvinyl alcohol or combinations thereof, and an oligomer of a polyamide.

Abstract: Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based powder, that constitutes the major portion of the composition. A silicon carbide-containing powder is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a “green” compact that is then sintered, preferably at relatively high temperatures.

Abstract: A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.

Abstract: Annealable insulated metal-based powder particles and methods of preparing and using the same are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.

Abstract: Methods of making and using annealable insulated metal-based powder particles are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.

Abstract: Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based or nickel-based powder, that constitutes the major portion of the composition. Silicon carbide is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a “green” compact that is then sintered, preferably at relatively high temperatures.

Abstract: Metallurgical powder compositions are provided that include silicon carbide to enhance the strength, ductility, and machine-ability of the compacted and sintered parts made therefrom. The compositions generally contain a metal powder, such as an iron-based or nickel-based powder, that constitutes the major portion of the composition. Silicon carbide is blended with the metal powder, preferably in the form of a silicon carbide powder. Optionally, common alloying powders, lubricants, binding agents, and other powder metallurgy additives can be blended into the metallurgical composition. The metallurgical powder composition is used by compacting it in a die cavity to produce a “green” compact that is then sintered, preferably at relatively high temperatures.

Abstract: Improved methods for coating particulate materials at low shear conditions and preferably below the melting point of the coating material are provided. In one aspect, metallurgical compositions are provided that contain a metal-based powder bound to an alloying powder or powders by way of a low melting polymer or wax binding agent, which is preferably polyethylene. The binding agent is blended with the metal-based and alloying powders at elevated temperatures preferably below the melting point of the binding agent. The bonded metallurgical composition can be used in compaction processes to manufacture compacted parts that can be sintered to impart strength.

Abstract: Metallurgical powder compositions are provided that contain a metal powder that is associated with a polymeric material in admixture with a solid, particulate polyether lubricant. The incorporation of the polyether lubricant enhances the green strength properties of compacted parts made from the powder compositions, and generally reduces the ejection forces required to remove the compacted part from the die cavity.