SINTERFLEX - Carbon Control in PM Sintering
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The presentation shows the Linde Gas SINTERFLEX technology for the PM Sintering industry and sharing background information on application in the industry for improving the quality of the PM parts in the sintering parts using the SINTERFLEX technology.
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SINTERFLEX - Carbon Control in PM Sintering
- 1. Quality Sintering. By Using New Furnace Atmosphere Control Technologies.
- 2. The Linde Group Organisational structure Engineering DivisionGases Division OtherActivities EMEA Asia/Pacific Americas The Linde Group The Group comprises three divisions: Gases and Engineering (the two core divisions) and Other Activities (Gist, the logistics service provider).The largest division, Gases, has three reportable segments: EMEA (Europe, Middle East and Africa), Asia/Pacific and the Americas, which are subdivided into eight Regional Business Units (RBUs). The Gases Division also includes the two Global Business Units (GBUs) Healthcare (medical gases and related maintenance and advisory services) and Tonnage (on-site supply of gases to major customers), as well as the two Business Areas (BAs) Merchant & Packaged Gases (liquefied and cylinder gases) and Electronics (electronic gases). Gist
- 3. The Linde Group worldwide Global presence in more than 100 countries
- 4. Gases used Oursolutions Neutral Hardening Nitriding /Nitrocarburising Gases used Oursolutions Gases used Oursolutions The Linde Group in Heat Treatment Industry CARBOFLEX HYDROFLEX CARBOJET CARBOCAT CARBOTHAN HYDROFLEX CARBOJET CARBOTHAN SINTERFLEX FRIOFLEX N2 Ar H2 HYDROFLEX CARBOTHAN CARBOJET CRYOFLEX CARBOFLEX FRIOFLEX NITROFLEXN2 H2 CO2 NH3 CO C2H2 N2 H2 C3H8 CH3OH CH4 He NH3 N2 Ar H2 CH4 CH3OH N2 Ar H2 CH4 CO CH3OH CRYOFLEX CRYOFLEX CARBOFLEX CARBOJET CARBOCAT CARBOTHAN N2 Ar CH4 CH3OH CRYOFLEX Annealing SinteringBrazing Carburising /Carbonitriding Gases used OursolutionsGases used Oursolutions Gases used Oursolutions
- 5. Raising the quality barforsintering quality Issues today: — a scatter as high as ±0.3 %C in sintering is not uncommon. — sinter steel parts are not regarded as safe alternatives to wrought fully dense products — strength and toughness of steels is determined by C-Content Solution: Having a process that is accurately controlled resulting in sintered parts with properties deviating to a minimum from required target values.
- 6. Sintering Furnace Atmosphere Functions and Linde Solutions in PMSintering Gas Humidifying SINTERFELXAtmosphere Control System SINTERFELXGas Generator SINTERFELXAtmosphere Circulation Nozzles SINTERFELXSinterHardening Atmosphere Analysing Atmosphere Analysing Methanol Bubbling Linde Solutions
- 8. Carbon Analysis of Brown Part by SEM SEManalysis of BASF CATAMOLDFN02 material has shown •up to 7% Carbon content locally in the mixture •average is about 4.8 % carbon in a bulk piece. Spektrum In Statistik C Cr Fe Mo Summe Spektrum 1 Ja 7.28 74.48 18.25 100.00 Spektrum 2 Ja 5.12 94.88 100.00 Spektrum 3 Ja 2.92 0.81 96.27 100.00 Spektrum 4 Ja 6.64 93.36 100.00 Spektrum 5 Ja 4.39 95.61 100.00 Spektrum 6 Ja 2.04 97.96 100.00 Spektrum 7 Ja 1.55 98.45 100.00 Spektrum 8 Ja 1.20 98.80 100.00 Spektrum 9 Ja 3.25 96.75 100.00 Spektrum 10 Ja 1.77 0.89 97.34 100.00 Max. 7.28 0.89 98.80 18.25 Min. 1.20 0.81 74.48 18.25
- 9. Carbon Balances and Theory in MIMProcess Brown Part (4.6% C Total) ~ 4% C from binder ~0.6% C from base carbon Desired final %C = 0.6% SINTERFLEXC-Potential Existing operation based on prediction of final Carbon content loss and very dependent on the de-binding performance at the time of production therefore variations may ormay not occur SINTERFLEX Controlled De-binding systemwill remove the excess carbon coming fromthe binder SINTERFLEXwill maintain the carbon in the base powderby providing neutral atmosphere 1 2 3 Reduced C- Content variation in final sintered batches
- 10. System Overview Complete integration and control of MIMSintering Process CO, H2, CH4 O2 mV Measured C-Potential calculated CO, H2, CH4 O2 mV Measured C-Potential calculated H2 carrier gas LPG trimming gas based on C-Potential Set-point H2 carrier gas LPGtrimming gas based on C-Potential Set-point Dew Point & Humidity Content Measured Dew Point & Humidity Content Measured N2 carrier gas Watervapour based on Humidity content Set-Point N2 carrier gas Watervapour based on Humidity content Set-Point
- 11. Carbon-Content variation in parts over8 hours
- 12. Benefits Effective C-Potential control allows — faster start up of operation and reduces switching times between different alloys — Reduces post treatment costs due to uniform C-Potential results after sintering — Enabling operators to sinter highly alloyed powders (Cr) — Reducing C-Potential scatter therefore achieving requirements from the Automotive industry — The new technology will allow the MIM Companies to reduce Hydrogen flows hence lower atmosphere costs. — Reduced Scrap — During the MIM part testing, the parts are controlled by destructive testing. When there is a potential reject in a batch, the Quality Control needs to destroy more parts for quality control. As the SINTERFLEX continues to run, the testing process will become less invasive to the procedure because the carbon results are more reliable. Instead of testing parts every three hours, it will be acceptable to test parts once or twice a day. → Significant cost reductions !
- 13. Atmosphere Circulation and Effective Internal Gas Generation
- 14. Gas Supply Capabilities Filling centre Pipeline Pipeline On-site supply Retailer Transport of liquefied gas Customer Cylinder Bulk Tonnage Gases production plant
- 15. Leading On-Site gas supply solutions ECOVAR More than 1,000 ECOVARsites worldwide. 100% reliability at low cost, low riskand full service on gas supply needs. Benefits of ECOVAR — Freedom to focus on core business — Transparent overview of long term costs — No upfront investment costs — No operating risk — No personnel expenditure — Zero maintenance and service effort — No need to keep spare parts on stock CRYOSS: Nitrogen Solutions HYDROSS: Hydrogen Solutions
- 16. Thankyou. Akin Malas Mobile: +49 (172) 5118036 E-mail: akin.malas@linde.com Web site: www.heattreatment.linde.com www.linkedin.com/in/akinmalas Join Linde Gas Heat Treatment TecPoint