Surface Modification of Steel Powders to Improve Processing and Properties

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Powder metallurgy is a common manufacturing route to mass-produce small to medium size complex shapes. Components are made net-shape through a compaction and sintering process and are typically made from steel or iron powders. Steel powders offer superior mechanical properties and it is the endeavor and Holy Grail of the manufacturer to attain properties close to those of wrought material. Elemental additives, such carbon, copper and nickel, are introduced as powders to improve the properties and aid in the compaction and sintering process. Lubricants and binders are also added at the compaction stage and must be removed during subsequent heat treatment. The current proposal is to explore the replacement of these additives by coatings with the goal to improve the processing and mechanical properties of the powder metallurgy parts.