Mark thomason

2019 July 11 – Ceramics UK
Mark Thomason
Gasbarre Products, Inc.

Powder Compaction Solutions
Thermal Processing Systems
Manufacturing Technologies
DENSIFICATION OF POWDER MATERIALS
• What densification means:
• Change powder bulk density to pressed density (increased density)
• Reduce/remove air/liquid from bulk materials
• Close packing of powder mix particles
• Mechanical working to interlock particles
• Develop sufficient strength for handling or possible green forming
• Conversion of bulk powder materials to high performance products

Methods utilized for consolidation (by force application
pressing):
▪ High productivity and pressed-in well defined features
▪ Shorter height parts
▪ Uniform density for engineered shrinkage
▪ Longer length parts
UNIAXIAL PRESSING
ISOSTATIC PRESSING

Methods utilized for consolidation (by force application pressing):
▪ Powder consolidation:
▪ Uniaxial pressing:
▪ Powder pressing
▪ Dry pressing
▪ Rigid die pressing
▪ Conventional pressing
▪ Isostatic pressing:
▪ Cold Isostatic Pressing (CIP):
▪ Wet
▪ Dry

INTRODUCTION

UNIAXIAL PRESSING ALTERNATIVES
• Mechanical presses:
• High speed:
• PTX Pentronix Anvil
• PTX Pentronix Opposed Ram
• Traditional:
• Push up ejection
• Withdrawal ejection/multilevel
• Hydraulic presses:
• CNC Servo Hydraulic Laboratory
• CNC Servo Hydraulic Production
• CNC Servo Hydraulic Multilevel
• Electric presses
• Hybrid presses
Uniaxial pressing (types of presses):

• High speed:
• PTX Pentronix Anvil:
• 4 Tons (up to 150 SPM) -> 35 Tons (up to 40 SPM)
• PTX Pentronix Opposed Ram Presses:
• 2 Tons (up to 100 SPM -> 35 Tons (up to 40 SPM)
ANVIL
OPPOSED
RAM

• Traditional:
• Push up ejection: 5 Tons -> 750 Tons
• Withdrawal ejection/multilevel: 5 Tons -> 800 Tons

Why Mechanical?
• Lower acquisition cost option; other types under 200 Tons
• Well-proven technology
• High productivity
• Reliable construction – Low maintenance
• Precision/repeatability: +/- 0.05 mm (0.002 in)
• Low floor space utilization

• CNC Servo Hydraulic Laboratory: 15 Tons -> 100 Tons
• CNC Servo Hydraulic Production: 15 Tons -> 1600 Tons
• CNC Servo Hydraulic Multilevel: 20 Tons -> 750 Tons

Why Servo Hydraulic?
• Pressing sequence flexibility:
• Special die control needs:
• Deep fills
• Dynamic filling:
• Gravity or suction filling
• Die height adjustment during fill box retract
• Die control for mold positioning:
• Density control
• Molding in stepped dies
• Special powder transfer needs
• Mold position/pressure dwell
• Efficiency:
• Velocities of up to 254 mm/sec (10 in/sec)
• Dynamic hydraulic pump speed management

• Electric presses:
• CNC Servo Electric:
• 3 Tons
• 6 Tons
• 15 Tons
• 20 Tons
• 30 Tons
Main features:
1) Rams:
a. Electric upper
b. Electric lower
c. Electric fill
2) Fully programmable

• Electric presses:
Why Servo Electric?
• Deep fills
• Density control
• Efficiency:
• Velocities of up to 371 mm/sec (14.6 in/sec)
• Low power consumption
• Clean, quiet, and reliable
• Low floor space utilization

• Hybrid presses:
• CNC Hydraulic/Electric:
• 30 Tons
• 60 Tons
• 150 Tons
• 250 Tons
Main features:
1) Rams:
a. Hydraulic upper
b. Electric lower
c. Electric fill
2) Fully programmable

• Hybrid presses:
Why Servo Hydraulic/Electric?
• Deep fills
• Density control
• Fill precision/repeatability: +/- 0.004 mm (0.00015 in) (for
thin parts)
• Efficiency:
• Velocities of up to 371 mm/sec (14.6 in/sec)
• Low power consumption – dynamic hydraulic control

• Additional Uniaxial Press Enhancements:
• Fluidized Die Filling Systems
• Die Wall Lubrication Systems
• Servo-electric fill systems for mechanical presses
• Automatic part extraction systems:
• Traditional pick and place systems
• Fanuc robot systems
• Automatic palletizing systems (possible inspection integration)

▪ Isostatic pressing:
▪ Cold Isostatic Pressing (CIP):
INTRODUCTION

CIP DRY BAG PRESSING ALTERNATIVES
APPLICATIONS

DRY BAG TOOL ARRANGEMENT

PRESSING SEQUENCE

• Simac Monostatic presses:
• Single cavity/pressure vessel
• Forming pressures up to 300 Mpa (44000 psi)
• Laboratory use: 2- 5 minutes/cycle
• Production use: 1-2 minutes/cycle*
• Parts up to 450 mm (17.7 in) length
• Fill diameters up to 180 mm (7 in)
• Parts as small as 3 mm (0.12 in) diameter x 200 mm (7.9 in) length
• Clamping forces: 100 Ton, 300 Ton, 400 Ton
• Simac Densomatic presses:
• Single cavity/pressure vessel up to 6 cavity/pressure vessels
• Forming pressures up to 240 Mpa (34800 psi)
• Production use: up to 8 cycles/minute*
• Parts up to 250 mm (10 in) length
• Fill diameters up to 80 mm (3.14 in)
• Fully automated
*note: cycle rates depend upon powder flow and compaction characteristics

• Simac Monostatic presses (up to 3000 bar/44000 psi):
• Series I:
• Laboratory use
• Piston pump forming pressure intensification
• Series II:
• Production use
• Piston pump forming pressure intensification
• Auto filling/automation available
• Series III:
• Production use
• Fast pressure cycle -> Advanced Forming Pressure System
• Auto filling/automation available
• Series IV:
• Production use
• Fast pressure cycle -> Advanced Forming Pressure System
• Automated

• Simac Monostatic Series I:

• Simac Monostatic Series II (HMI included):

• Simac Monostatic Series III
(Advanced Forming Pressure System): SIII
PRESSURIZATION

• Simac Monostatic Series IV
(Fully Automatic):

• Simac Densomatic
DENSOMATIC

• Simac Densomatic presses:
Densomatic Press Specifications
Maximum Speed
(min-1)
Maximum Fill Diameter Maximum Part Length Maximum Isostatic Pressure
Capacity Model Cavities mm inches mm inches bar psi
5 Ton 1/5/570 1 2 23 0.91 120 4.72 570 8265
15 Ton 1/15/2100 1 2 23 0.91 114 4.5 2100 30450
16 Ton 6/16/830 6 30 30 1.18 120 4.72 830 12035
4/16/2100 2 5 20 0.79 120 4.72 2100 30450
20 Ton 2/20/520C 2 10 23 0.91 140 5.51 520 7540
6/20/520C 6 10 23 0.91 90 3.54 520 7540
30 Ton 6/30/800 6 12 23 0.91 105 4.13 800 11600
3/30/2100 3 2.5 23 0.91 105 4.13 2100 30450
40 Ton 4/40/2000 4 16 80 3.15 120 4.72 2000 29000
65 Ton 4/65/600 4 12 80 3.15 170 6.69 600 8700
4/65/2100 4 12 105 4.13 125 4.92 2100 30450
125 Ton 6/125/2100 6 4.5 28 1.13 114 4.50 2100 30450
150 Ton 3/150/800 3 7.5 80 3.15 230 9.06 800 11600
180 Ton 1/180/1000 1 1 80 3.15 200 7.87 1000 14500
200 Ton 2/200/2400 2 2 60 2.36 60 2.36 2400 34800

PRESSING ALTERNATIVES
FOR FURTHER INFORMATION:
WEBSITE: www.gasbarre.com
EMAIL: press-sales@gasbarre.com

Mark thomason

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