High Integrity Powder Metallurgy (HIPM) for advanced diesel and

High Integrity Powder Metallurgy (HIPM) for advanced diesel and gasoline injec;on systems Engine Expo – Technology forum 2015 Stu:gart – Germany June 16th 2015 O Finot (Erasteel), F Devilder (Aubert&Duval) ALLOYS, ORES & PEOPLE.
E-­‐Mail: olivier.finot@eramet-­‐erasteel.com www.erasteel.com INTRODUCTION: Example: OEM raw material requirements for HD Diesel Injec;on •  High fa8gue performance (cleanliness + mechanical proper8es YS/Hardness) at high pressure up to 4 000 bar in Heavy Duty / 1,6 Mio km warranty è 2 Bio cycles • 
Temperature resistance up to 400°C • 
High wear/erosion-­‐cavita8on resistance in specific areas • 
• 
• 
• 
Impact toughness for safe handling Suitability for surface enhancement (coa8ngs, nitriding) Absence of carbide pull-­‐out for 8ghtness Isotropy to resist complex loading pa>erns in high pressure systems NOx •  Corrosion resistance due to exhaust gas re-­‐injec8on into engine combus8on chamber for be>er performance •  Machinability for good surface finish and cost minimisa8on EURO 7 in progress This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
Par;cles 2 INTRODUCTION: Example: OEM raw material requirements for HD Diesel Injec;on Pressure Heat Wear Endurance (cycles) Hardness/UTS Hardness/Temper resistance Hardness/ Carbides Chemical composi;on/ Alloy system Process HRC> 58 High Speed Steel Tool Steels Powder Metallurgy Inclusion control Fa8gue resistance This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
3 Outline of presenta;on q  HIPM – Grades and process Ø  Microstructure Ø  PM ASP® process q  HIPM -­‐ Core proper;es Ø  Hardness -­‐ Temper resistance Ø  Wear resistance Ø  Impact toughness + Fa;gue q  HIPM -­‐ Addi;onal proper;es Ø  Corrosion resistance Ø  Machinability Ø  Small components in as hardened condi;ons : LINEA® q  Conclusion This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
4 Outline of presenta;on q  HIPM – Grades and process Ø  Microstructure Ø  PM ASP® process q  HIPM -­‐ Core proper;es Ø  Hardness -­‐ Temper resistance Ø  Wear resistance Ø  Impact toughness + Fa;gue q  HIPM -­‐ Addi;onal proper;es Ø  Corrosion resistance Ø  Machinability Ø  Small components in as hardened condi;ons : LINEA® q  Conclusion This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
5 Grades and process q  Small, homogeneous, isotropic microstructure M2
ASP® 2023
LOM
MC
(2800 HV)
M6 C
Martensitic matrix + carbides (nitrides)
Mo
Carbide former (M6C)
W
Carbide former (M6C)
V, Nb
Carbide former (MC)
Partial dissolving
Secondary hardness
Cr
Carbide former (M23C6/M7C3)
Dissolved in matrix
Secondary hardness
Co
Dissolved in matrix
Hardness (“hot hardness”)
(1600 HV)
MATRIX
(800 HV)
A
microstructural
advantage
1 µm
This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
6 Grades and process Typical composition
Grade Norm. Des. Maximum Hardness C Cr Mo W V Co Typical applica;on (transporta;on + racing) M2 1.3343 65 HRC 0.9 4.2 5.0 6.4 1.8 -­‐ Injec8on systems and pumps M50 1.3551 64 HRC 0.8 4 4.2 0 1.1 -­‐ Bearings and pumps T1 1.3355 65 HRC 0.75 4 0 18 1 -­‐ Injec8on systems and pumps ASP®2012 1.3397 58 HRC 0.6 4,0 2,0 2,1 1,5 -­‐ F1 cam sha^ ASP®2005 1.3377 64 HRC 1,5 4,0 2,5 2,5 4,0 -­‐ Injec8on systems and pumps ASP®2017 1.3288 65 HRC 0,8 4,0 3,0 3,0 1,0 8,0 1,0% Nb Injec8on systems and pumps ASP®2023 1.3395 66 HRC 1.3 4.1 5.0 6.4 3.1 -­‐ F1 Bearings and tappets ASP®2042 1.3247 69 HRC 1.1 3.8 9,4 1,5 1,2 8,0 Injec8on systems and pumps APZ10 X120CrMoVN19-­‐2 62 HRC 1.15 19 2.1 -­‐ 0.6 -­‐ Injec8on systems This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
7 Grades and process ASP®2017
A wide range of microstructures
ASP®2012
ASP®2005
ASP®2023
ASP®2042
MC
(2800 HV)
M6 C
(1600 HV)
10 µm
This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
8 Grades and process q  Very rapid cooling of individual powder grains q  Segrega8on only possible within grains q  Average powder size around 100µm, compared to typical several 100 kg’s for ingot Some process characteris;cs q  Heated synthe8c slag Protec8on of the melt, de-­‐oxida8on and temperature control q  Argon bubbling Temperature homogeniza8on and inclusion separa8on q  Delayed opening Time for refining of steel in tundish q  Stable ceramic and linings Selec8ons of ceramic and lining material
for minimum amount of exogenous inclusions q  Gas 8ght tower Minimum oxida8on of powder 100 um Gas atomized metal powder
q  Closed system From top of tower to filling in capsule è No external air/dust contamina8on This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
9 Outline of presenta;on q  HIPM – Grades and process Ø  Microstructure Ø  PM ASP® process q  HIPM -­‐ Core proper;es Ø  Hardness -­‐ Temper resistance Ø  Wear resistance Ø  Impact toughness + Fa;gue q  HIPM -­‐ Addi;onal proper;es Ø  Corrosion resistance Ø  Machinability Ø  Small components in as hardened condi;ons : LINEA® q  Conclusion This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
10 Core proper;es of HIPM Hardness and temper resistance
Wear resistance
q  Adhesive wear: Smooth surfaces + nitriding q  Abrasive wear: Nitrided
ASP®
Hardness, carbides (types, fv, sizes) q  Cavita8on/erosion wear: Hardness, carbides fv, fa8gue resistance ASP®
100Cr6 ASP®2012
ASP®2005
Carburising grades FND Nitriding grades H13 Tool steels ASP®2017
• Hard matrix
• Hard carbides
• Many carbides
This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
11 Core proper;es of HIPM Fatigue resistance (Rotative bending 20 M Cycles, 20mm stock)
Lf rota;ve bending (MPa) 1400 ASP®2042 ASP®2005 1200 HIPM
1100 ASP®2017 ASP®2012 1000 M50 VIM/VAR Effect of process
Fa;gue Lf (20Millions cycles) -­‐ MPa 1300 900 800 700 100Cr6 Ultra Clean Tool steel M2 M50 Conventional
Steel grades
Fracture initiation at a non-metallic
inclusion/ HIPM-HSS (fatigue testing)
600 50 52 54 56 58 60 62 64 66 68 70 Core hardness (HRC) This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
12 Core proper;es of HIPM Fatigue resistance : Small carbides, reliable Cleanliness
2005-2009
2010 è
HIPM
This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
13 Core proper;es of HIPM Fatigue resistance : Reliable Cleanliness
Typical ASTM E45 method D ratings of ASP material
Type A
0.5
1.0
Thin
Thick
Thin
Thick
0,08
0,08
0,08
Type B
0.5
Thin
0
1.0
Thin
Thick
0
0
Thick
0
Type C
0.5
1.0
Thin
Thick
Thin
Thick
0
0,17
0,17
0,08
1.5
Thin
0
Thick
0,04
Type D
0.5
1.0
Thin
Thick
Thin
Thick
0
0,08
0,08
0,04
0
q  Cleanliness: HIPM cleanliness level makes standard ASTM/DIN ra8ng inappropriate q  Fa8gue tes8ng: Vehicle components > x B cycles/ Property characteriza8on: 20 M cycles: Too expensive q  Cleanliness level related to a sum of key process steps which must be controlled è HIPM q  Necessity to develop a specific quality control method for process improvement and control àFast, cost efficient, representa8ve This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
14 Core proper;es of HIPM Fatigue resistance : In-house uniaxial pull-pull fatigue test
q  Fa8gue strength at 2 M cycles, Pull-­‐pull (no compressive stresses), staircase method with 8-­‐12 samples and 50MPa step length, samples from 120 mm bar. q  Specific test piece manufacturing: fine finished with hard turning and excellent surface finish condi8ons This fa8gue test has enabled ERASTEEL to establish a standard for HIPM material quality regarding cleanliness induced by process paramters. Key process parameters to meet HIPM requirements are under control This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
15 Core proper;es of HIPM Years
1970-1990
1990-2004
2005-2009
2010à
Metallurgy
Applications
Standard PM HSS
ESH PM HSS
Improved quality
of ASP® to HIPM
opens up for
more
applications
ESH and Dvalin™
HIPM
This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
16 Outline of presenta;on q  HIPM – Grades and process Ø  Microstructure Ø  PM ASP® process q  HIPM -­‐ Core proper;es Ø  Hardness -­‐ Temper resistance Ø  Wear resistance Ø  Impact toughness + Fa;gue q  HIPM -­‐ Addi;onal proper;es Ø  Corrosion resistance Ø  Machinability Ø  Small components in as hardened condi;ons : LINEA® q  Conclusion This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
17 Addi;onal proper;es of HIPM •  62HRC matrix •  M7C3 + M23C7 carbides Corrosion resistance
q  APZ10 •  Martensi8c Stainless Steel Mel;ng route C 440C Air or Remelt 1.0 17.0 -­‐ -­‐ 0.50 -­‐ -­‐ -­‐ -­‐ APZ10 Air/PM 1.1 19 -­‐-­‐ 2.1 0.6 -­‐-­‐ Pitting index =
Cr + 3,3 Mo +16N
Ni Mo V N Fa;gue Lf (20Millions cycles) -­‐ MPa A&D Grades Cr Lf rota;ve bending (MPa) 1400 ASP®2042 1300 ASP®2005 APZ10 1200 ASP®2017 1100 ASP®2012 1000 X15TN 900 Grade Tempering T°C PI 440C 140 14,5 440C 450 4,5 700 APZ10 180 19 APZ10 510 5 600 440C 800 50 55 60 Core hardness (HRC) This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
65 70 18 Addi;onal proper;es of HIPM Improved machinability without performance loss through micro S-addition
q  External tests run at customers on 2 versions of ASP®2005: •  ASP®2005 Ø 15 mm stock hardened at 64 HRC •  Turning at Vc = 70 m/mn , 1500 rpm, fz = 0,02 mm/tooth •  Beder surface finish / lower surface roughness (Ra) a^er hard turning of the micro-­‐sulfurized grade: Ø  ASP® 2005: Ra = 0,2 µm Ø  Micro-­‐sulfurized ASP®2005 : Ra = 0,1 µm q  Fa8gue limit:
Rota8ve bending fa8gue tes8ng R-­‐1 -­‐ 20 Mio cycles Samples from Ø15mm Ø20 mm
ASP®2005S (0.15%S) Longitudinal cut Fa;gue limit (MPa) 1200 1000 800 600 400 200 0 ASP2005 ASP2005+S (1000°C) (1075°C) This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
ASP2005+S (1000°C) 19 Addi;onal proper;es of HIPM Hard machining (grinding) on pre-hardened material
q  LINEA® process approved for valve pin applica8ons q  Capable from Ø1,2 to Ø3,4 mm q  Hardness up to 69 HRC with ASP®2042 q  Excellent grindability: extra small MC or M6C carbides q  Outstanding straightness q  Limited residual stresses q  Limited decarburiza8on Sample
∑MxCy (%)
Phase α (%)
Retained γ (%)
Std devia;on γ (%)
Ǿ2.3mm bar
20.4
78.9
0.7
0.2
Ǿ2.3mm bar (2h at -­‐40°C + 2h at 250°C)
22.5
76.8
0.7
0.2
ASP® 2017
ASP®2042
MC
(2800 HV)
M6 C
(1600 HV)
q  Very low Retained γ (%) for dimensional stability
This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
20 Outline of presenta;on q  HIPM – Grades and process Ø  Microstructure Ø  PM ASP® process q  HIPM -­‐ Core proper;es Ø  Hardness -­‐ Temper resistance Ø  Wear resistance Ø  Impact toughness + Fa;gue q  HIPM -­‐ Addi;onal proper;es Ø  Corrosion resistance Ø  Machinability Ø  Small components in as hardened condi;ons : LINEA® q  Conclusion This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
21 Conclusion q  With millions of components in the field star8ng from 2012, high integrity PM high-­‐speed steels such as ASP 2005 ® have been shown to be reliable materials for demanding HD injec8on system components as a consequence of the combina8on of high hardness, fine microstructure, full density and controlled cleanliness, bridging the gap between construc8on/carburizing steels and ceramics. q  Demonstrated poten8al for future use in: •  Gasoline injec8on (PM Martensi8c Stainless Steels) •  Other components diesel (fuel injec8on pump components such as cam rollers) •  Medium + light duty injec8on systems (eventually!) q  Component costs can even be improved thanks to micro resulfuriza8on with minor performance decrease or with prehardened bar supply This Document contains confidential and proprietary information of Erasteel and shall not be reproduced,
distributed or disclosed to any third party without prior written consent of Erasteel
22