Density Distributions in Complex Shaped Parts Made from Iron Powders

Abstract

A series of specially shaped punches, operated in pairs, made possible the manufacture of 37 different, but related, shapes. Four iron powders with four levels of zinc stearate (0·5, 1·0, 1·5, and 2·0 wt-%) were compacted into these shapes to densities in the range 5·3–7·05 Mg m⁻³, using an instrumented industrial press. The effects of the following variables on the density distribution within each component were examined: iron powder type and characteristics, lubricant type and content, size (height to diameter ratio), shape, density, and compaction pressure. The information obtained for the series of shapes enabled conclusions to be made on the way that material characteristics, pressing conditions, and restrictions on shape control the density distribution within the final component. These data gave clear indications that will be useful in designing a component for efficient production. PM/0314