EU project looks to demonstrate feasibility of High-Density Powder Metallurgy process

April 17, 2018

LIFE 4GreenSteel is an EU/industry funded project which aims to demonstrate the feasibility of replacing traditional energy-intensive and material-consuming machining of wrought metals with a new and innovative High-Density Powder Metallurgy (HDPM) technology. In particular, the project is reported to be focusing on the manufacture of high-performance steel gears for the automotive market, utilising the recognised green credentials of the Powder Metallurgy process.

The high mechanical and dimensional requirements could, it is stated, be theoretically met by means of an innovative Die Wall Lubrication (DWL) compaction stage, in combination with high-temperature vacuum sintering and thermochemical treatment. The DWL compaction process is currently used only in a limited number of applications and has not yet been exploited at an industrial level due to the difficulties of planning, managing and monitoring the production process.

The project, coordinated by Italy’s TFM Automotive & Industry S.p.A, with partners including press manufacturer Sacmi, R&D company K4Sint, and the University of Trento, is expected to show a reduction in the use of raw materials by some 47% and energy savings of 50%, compared to the traditional machining process. Targets include the development of an effective pressing system to produce sintered steel parts that have a density greater than 7.3 g/cm3 and high dimensional stability. It will tailor the high-temperature vacuum sintering stage and develop a reliable case-hardened profile of PM steel by means of the thermochemical treatment Low-Pressure Carburising (LPC).

In addition, the partners will use a chemical composition for steel that avoided harmful alloying elements, such as nickel, or alloying elements that make the recycling process difficult and ineffective, such as copper. It is stated the process will reduce by more than 70% the lubricant premixed with metal powder, so eliminating the burning stage, increasing energy efficiency and solving related emission problems.

LIFE is a financial division of the European Union that supports environmental safeguarding, nature conservation and climate change action projects. Since its founding in 1992, it has funded over 4,500 projects.

www.tfmgroup.it

www.sacmi.it

www.unitn.it

www.k4sint.com

In the latest issue of PM Review…

Download PDF

Extensive Powder Metallurgy industry news coverage, and the following exclusive deep-dive articles and reports:

  • Burgess-Norton and Amsted Automotive: How a legacy automotive supplier is growing with, not despite, electrification
  • Meeting sustainability demands in PM: High-temperature sintering of nickel- and copper-free powder mixtures for low alloyed PM parts
  • World PM2022: An overview of the status and trends in the global PM industry
  • A novel approach for the production of metal powders with tailored chemical compositions: Amazemet’s rePowder
  • Productivity, flexibility, reliability: SACMI’s new press technologies for the changing PM industry
  • Understanding the thermal properties of metal powders: Characterisation of powders using the Hot Disk technique
  • World PM2022: Views on the potential of Field Assisted Sintering for advanced materials

The latest news from the world of metal powders, delivered to your inbox

Don't miss any new issue of PM Review, and get the latest industry news. Sign up to our weekly newsletter.

Sign up

From the industry…

Discover our magazine archive…

The free-to-access PM Review magazine archive offers unparalleled insight into the world of Powder Metallurgy from a commercial and technological perspective through:

  • Reports on visits to leading PM part manufacturers, metal powder manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

 

Browse the archive

 

Looking for PM production equipment, metal powders, R&D support and more?

Discover suppliers of these and more in our
advertisers’ index and buyer’s guide, available in the back of PM Review magazine.

  • Powders & materials
  • Powder process, classification & analysis
  • PM products
  • Atomisers & powder production technology
  • Compaction presses, tooling & ancillaries
  • Sintering equipment & ancillaries
  • Post-processing
  • Consulting & toll sintering
Download PDF
Share via
Copy link