Effect of Sintering Parameters and Powder Characteristics on the Performance of Metal-Injection-Molded SKD 11 Parts
—Metal-injection-molded parts were fabricated using three kinds of SKD11 powder under different sintering parameters and with different binders and additives. An analysis of the microstructures and mechanical properties of these metal-injection-molded parts revealed that the porosity decreased and the grain size increased when the sintering isothermal holding increased. The average grain size was smaller for the part made of gas-atomized powder than for that made of water-atomized powder under the same sintering condition. The microstructures consisted of (Fe,Cr) solid solution substrates and Cr 7 C 3 carbide precipitates for the sintered part. For the specimen containing 10 wt % Fe, the mechanical property decreased due to less chromium carbide precipitates. The wear resistance and hardness of the sintered part made of gas-atomized powder were superior to those of the part made of water-atomized powder. In the pin-on-disk wear test, adhesive wear and a lower friction force were observed on the specimen with a lower hardness value. On the other hand, abrasive wear and a higher friction force were found for the specimen with a higher hardness value.
Wear behavior and mechanical performance of metal injection molded Fe–2Ni sintered components
Abstract The microstructure, mechanical properties, and wear behavior of two key components of a hinge fabricated from a metal injection molding process that was then sintered and heat treated under various conditions were analyzed using an optical microscope, a pin-on-disk tester, an open-closed reciprocal wear tester, and a scanning electron microscope. Optical photomicrograph revealed a serious decarburization in the sintered component, suggesting that an increase in carbon content would be necessary to improve mechanical properties. At the initial stage of the open-closed reciprocal wear test, the obverse inclined planes of both components exhibited plastic deformation and depression. As the number of test cycles increased, an increase in cold welding, metal adhesion, spalling, delamination, and surface fatigue was observed, triggering a decrease in metal thickness, which in turn altered the shape of the components. In this study, the optimal parameters to satisfy commercial application requirements were obtained when the components were carburized at 870 °C for 30 min, quenched in oil, and finally tempered at 250 °C for 1 h.
Neutron Residual Stress Measurements on Rail Sections for Different Production Conditions
Rail sectioning with subsequent neutron diffraction experiments has been used to assess residual stresses in the rails. In this study we present the results of neutron stress measurements performed at the NIST Center for Neutron Research (NCNR) on rail sections from rails that were produced under various conditions. Specifically, these are air-cooled, air-cooled and roller-straightened, head-hardened and head-hardened and roller-straightened. More significantly, a head-hardened and roller-straightened rail was also studied after service to elucidate evolution of the service-induced residual stresses. In the latter case both a transverse-cut slice and the central region of a 0.53 m long piece were studied. Measurements on this piece are the first in which triaxial stresses have been determined for an intact rail. Neutron strain measurements with 3×3×3 mm3 spatial resolution were successfully employed for transversally cut slices to verify the difference in the stress state depending on the production process. Although examination of slices allows determination of only two-dimensional stresses in the plane of the slice, additional measurements on obliquely-cut slices, which were also carried out, and utilization of FEM gives the possibility of reconstructing the full triaxial stress distribution. Together, these approaches provide a better understanding of rail fabrication and the possibility of improving the durability and safety of rails in the future.Copyright © 2004 by ASME