Reaching high density in PM steels is important for high-performance applications. In this study, liquid phase sintering of PM steels by adding gas-atomized Ni-Mn-B master alloy was investigated for enhancing the density levels of Fe- and Mo- prealloyed steel powder compacts. The results indicated that liquid formation occurs in two stages, beginning with the master alloy melting (LP-1) below and eutectic phase formation (LP-2) above 1373 K (1100 °C). Mo and C addition revealed a significant influence on the LP-2 temperatures and hence on the final densification behavior and mechanical properties. Microstructural embrittlement occurs with the formation of continuous boride networks along the grain boundaries, and its severity increases with carbon addition, especially for 2.5 wt pct of master alloy content. Sintering behavior, along with liquid generation, microstructural characteristics, and mechanical testing revealed that the reduced master alloy content from 2.5 to 1.5 wt pct (reaching overall boron content from 0.2 to 0.12 wt pct) was necessary for obtaining good ductility with better mechanical properties. Sintering with Ni-Mn-B master alloy enables the sintering activation by liquid phase formation in two stages to attain high density in PM steels suitable for high-performance applications.

A novel approach to reach full density in powder metallurgy (PM) components is demonstrated in this work. Water-atomised Mo-prealloyed steel powder is utilised for manufacturing cylindrical and gear samples through double pressing and double sintering (DPDS) process route. The effect of sample geometry and powder size fraction on densification is investigated and it is found that the DPDS route enables a density level of > 95% which is sufficient to eliminate the surface open pores. Reaching such high density is necessary, in order to perform capsule-free hot isostatic pressing (HIP). After HIP, full densification is achieved for the cylindrical samples and only near full density is realised for the gears resulting in neutral zone formation due to the density gradient. In order to predict the densification behaviour during the compaction, FEM simulations considering the gear geometry are performed for both the pressing stages and HIP. The simulation predicted a similar densification behaviour with the formation of the neutral zone. The proposed DPDS route with capsule-free HIP in combination with FEM simulation is demonstrated as a potential route for manufacturing full-density PM steel components, e.g. gears, suitable for high-performance applications.

Powder metallurgy (PM) steel with enhanced density is essential for meeting the demands on high strength and high-performance applications. In this study, cold isostatic pressing (CIP) is applied for consolidating water-atomised iron and Cr-alloyed steel powder to reach about 95% densification before sintering. Additionally, the effect of the lubricant and graphite addition on the compressibility of the different base powder types was evaluated. The maximum green densities of ≈7.55 g cm⁻³ for iron powder and ≈7.45 g cm⁻³ for Cr-alloyed powder were reached after CIP at 800 MPa. The sintering at 1250°C with added graphite allowed to achieve increased densification to ≈7.60 g cm⁻³ for the iron and ≈7.50 g cm⁻³ for Cr-alloyed grades, respectively. These levels were sufficient for surface pore closure, which allowed the application of the capsule-free hot isostatic pressing (HIP) after sintering to reach full density. This approach paves the way for manufacturing large-sized PM components.

The precipitation of V and Cu in the powder forged connecting rods of Fe-V-Cu-C alloy, were studied by atom probe tomography (APT). The purpose of alloying with V was to further improve the mechanical properties of the existing powder forged materials based on Fe-Cu-C. In this study, materials tested at room temperature and 120°C were investigated. It was found that Cu was unevenly distributed on a micrometer scale. The local Cu content affected the Cu precipitation; a higher Cu content resulted in a higher volume fraction of precipitates. The V was found to form very small nitrides. The N presumably originates from the sintering process. The vanadium nitrides act as nucleation points for the Cu precipitates during cooling of the material during fabrication. APT analysis of the deformed material close to the fracture surface of the tensile test samples showed a similar volume fraction of Cu precipitates, but statistical analysis of the data indicates that both Cu and VN precipitates are more diffuse than in the undeformed material.

In PM steels, alloying through master alloy (MA) addition enables the introduction of oxygen-sensitive elements such as Cr, Mn, and Si. These elements offer cost-effective and sustainable alternatives to Cu and Ni, enhancing hardenability and performance. This study investigates the atomisation of Fe-Cr-Mn-Si-C MA powders using three different techniques: water atomisation, gas atomisation, and gas atomisation-water cooling. The MA powders were sieved into two size fractions and mixed with Fe – 0.85 wt.% Mo pre-alloyed base powder and graphite. MA powder characterisation, compressibility, and dilatometry-sintering experiments were performed to evaluate the different atomisation techniques, and liquid phase formation at various sintering temperatures. Additionally, industrial sintering trials were conducted, and mechanical properties were assessed to understand the behaviour of sintered samples. The results indicate that MA addition improves the hardenability and performance, especially after sintering above 1200°C, once the MA melting and alloy homogenisation have occurred.