Mixed Powder Lubricant System for Ejection and Fluidity
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Solution Overview
Problem
Existing mixed powders for powder metallurgy require special production processes for lubricants with different melting points, increasing production costs and complexity, while also facing issues with fluidity, ejection properties, and compressibility due to the use of low-melting-point lubricants.
Innovation Solution
A mixed powder composition comprising an iron-based powder and a lubricant with a combination of low-melting-point and high-melting-point components, where the low-melting-point lubricant has a melting point of 86°C or less and the high-melting-point lubricant has a melting point of more than 86°C, with specific ratios and forms to enhance fluidity and ejection properties without the need for special production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a low-melting-point lubricant is used to improve ejection properties, then ejection force is reduced, but fluidity of the mixed powder deteriorates
Solution Approach 1:
The patent combines a low-melting-point lubricant (melting point 50-80°C) and a high-melting-point lubricant (melting point 100-150°C) in a mass ratio of 7:3 to 3:7. The low-melting-point component provides excellent ejection properties by reducing friction between the green compact and die wall, while the high-melting-point component maintains powder fluidity and prevents segregation during mixing and handling.
2Strength
If a lubricant with strong adhesive power is used to improve binding, then binding strength is improved, but fluidity of the mixed powder deteriorates
Solution Approach 1:
The patent changes the melting point parameter of the lubricant by using a dual-component system. The high-melting-point lubricant (100-150°C) provides strong adhesive power for binding alloying powder and additives to the iron-based powder surface, while the lower-melting-point component (50-80°C) ensures adequate fluidity. This parameter optimization allows the lubricant to exhibit both strong binding and acceptable fluidity.
3Stability of the object's composition
If a binder is added to prevent segregation, then segregation resistance is improved, but the total amount of binder and lubricant increases
Solution Approach 1:
The patent makes the lubricant serve multiple functions: it acts as both a lubricant (providing ejection and compression properties) and as a binder (preventing segregation of alloying powder and additives). The dual-component lubricant system with specific melting points enables it to perform both binding and lubrication functions effectively, eliminating the need for separate binder and lubricant additions.
4Ease of operation
If the total amount of lubricant and binder is increased to improve ejection properties, then ejection force is reduced, but density of the green compact decreases
Solution Approach 1:
The patent optimizes the melting point parameters of the lubricant components and their mass ratio to achieve effective ejection properties with minimal total lubricant content (0.05-0.5 mass%). The low-melting-point component (50-80°C) provides excellent ejection by reducing friction, while the high-melting-point component (100-150°C) ensures proper green compact density by maintaining appropriate lubrication during compaction without excessive lubricant addition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides excellent fluidity, ejection properties, and compressibility during compaction, allowing for the use of readily available lubricants without additional production costs and preventing segregation of components, while avoiding the use of metal soaps that cause furnace stains during sintering.
Implementation Method 1
The lubricant has a lubrication effect when the mixed powder is subjected to compaction in a die. The lubrication effect is further roughly divided into the following two. One is the effect of reducing the friction between particles contained in the mixed powder. During the compaction, the lubricant enters between the particles and reduces the friction
Implementation Method 2
The lubricant on the surface of the die enters between the die and the particles, thereby reducing the friction between the die and the particles
Implementation Method 3
the lubricant has stronger adhesive power than the iron-based powder
Implementation Method 4
the additive components be adhered to the surface of the iron-based powder via a binder
Data Source
AI summary
A mixed powder for powder metallurgy comprises: an iron-based powder; and a lubricant, wherein the lubricant consists of a low-melting-point lubricant having a melting point of 86° C. or less and a high-melting-point lubricant having a melting point of more than 86° C., the low-melting-point lubricant has at least one of an amide group, an ester group, an amino group, and a carboxyl group, a ratio R1 of the low-melting-point lubricant to whole of the lubricant is 5 mass % or more and less than 90 mass %, a ratio R2 of a mass of a free lubricant to a mass of a binding lubricant is 0 or more and 15 or less, and an amount R3 of the low-melting-point lubricant contained as the free lubricant is less than 0.10 parts by mass with respect to 100 parts by mass of the iron-based powder.