THE FORGING OF POWDER METALLURGY PREFORMS by Joel S. Hirschhorn and Roger B. Bargainnier The forging of powder metallurgy preforms in closed dies is a relatively new technology, especially for ferrous materials, The best features of two estab- ished technologies are melded into a manufacturing process that offers increased design freedom and im~ proved properties at reduced costs for a variety of engineering components, This review emphasizes a discussion of the unique technical and economic aspects of the process, the latitude of possible process variations, and the need for development work in potential problem areas, INTRODUCTION Of the metal working techniques that are based on the use of powders, green (as-pressed) compacts or sintered materials, the one that offers the greatest potential for widespread commercial exploitation is the hot forging of powder metallurgy preforms in closed dies. This area of “P/M forging,” particularly with regard to ferrous materials, will be critically re- viewed, The subject is difficult to treat because it involves two different technologies and presently there is a dearth of published data necessary to com- pletely evaluate the process. There is a need not only. for research in several areas (to be discussed), but also for improved dissemination of information gen- erated in industry, and for greater communication between specialists in powder metallurgy and forg- ing. J. S, HIRSCHHORN is Associate Profesor of Matollrgicol Engineer. ing ot the University of Wisconsin, Medison, Wisconsin. R. B. BAR- GAINNIER iz current oztocioted withthe Univesity of Wisconsin while on leave from the Chemical ond Metllusicl Dit, Sylvania Electie Products, In. Paper presented at the Second Inter Ameri- can Conference on Matrils Technolgy, Mexico City, August 24-27, 1990 ra semen DENSITY (Ye theoretical) Fig. 1Dependence of impact strength on density for two diferent types of iron powder forgings? PREFORM FABRICATION It is the manufacture of the forging preform that is based on powder metallurgy technology. In this see- tion the basie aspects of preform manufacture will be considered, and in the subsequent one its design and control. The first major problem is the selection of the powder from which to make the preform. There is a host of powder and particle characteristics of importance with respect to the fabrication of a com- pact.’ A most important point is that these character- SEPTEMBER 1970, JOURNAL OF METALS—21istics take on greater or lesser importance when considering P/M forging preforms relative to con- ventional P/M products. The most important of these factors will be discussed Powder purity and the precise nature and form of the impurities present are extremely important for preforms. The rather large amounts of porosity in ‘most conventional P/M parts signify that virtually all properties are considerably less than those of an equivalent material at full theoretical density. How- ever, for P/M forgings, at or near full density, the dominant effect of residual porosity on properties is replaced by classical metallurgical considerations re- lated to property degradation. Most important is the effect of impurity inclusions, particularly on ductility and impact strength. Some methods of powder pro- duction tend to cause nonmetallic inclusions 10 be present in the resulting powder. This is usually the case for reduction techniques, such as the reduction of iron ores or mill seale, Unreduced oxides or other mineral impurities are likely to be unaffected by sub- sequent processing. On the other hand, powders pro- duced by atomization of a molten metal or by elec- trolytie deposition tend to have higher purities and fewer, if any, impurity inclusions. This effect is illustrated quite forcefully in Fig. 1 ‘The impact strength of two types of pure iron P/M. forgings is shown as a function of density. The high purity atomized powder leads to the normal sharp increase in strength as full density is approached, However, the sponge iron type, which contains sub- stantial amounts of inclusions, does not show this im- provement—without which the forging of P/M pre- forms has no meaning or commercial significance, ‘Thus, there will be greater emphasis on the use of the highest purity and often more costly powders for forging preform manufacture, ‘The particle size distribution is likely to have a sig- nificant effect on the preform forgeability and on the properties of the final product. This may be related to differences in impurity content, grain size, or the amount and nature of porosity. There has been little ‘work in this area. There is some indication for fer- rous preforms that larger amounts of the coarser size fractions are beneficial, or at Ieast not detrimen- tal. This could lead to lower powder costs because such fractions are usually removed or minimized, at added cost, for powders used for conventional P/M products. Data illustrating a particle size effect for beryllium P/M forgings are given in Fig. 2. Although the total ‘oxide content and final grain size were similar for the two types of powders, the smaller particle size led to the highest impact strength for the optimum post- forging heat treatment of 1400°F (760°C), es- pecially at the lower forging temperatures. The pre- cise nature of the residual oxide dispersoid in such forgings is the likely reason for the differences ob served. Similar results were found for yield and ten- sile strengths. 22—JOURNAL OF METALS. SEPTEMBER 1970 400 F treatment 1900 F treatment 20 Micron Impact Energy, felb F 1400 1600 Ye00 2000 ei ey c ‘300 900 ‘000 Toe Forging Temperatures Fig. 2Dependence of impact strength on forging temperature for 1400" (760°C) for 8 hr ond furnace ci 1900°F (1038°C) for 6 hr and quenched i Because alloys and not pure metals will represent the bulk of P/M forgings one must carefully consider powder composition for preform use. Traditionally, in powder metallurgy, either a mixture of the appro- priate powders (such as iron and graphite for steel) ‘or a prealloyed powder made by atomization in which each particle is the true alloy has been used. The major disadvantage of the first approach is that a subsequent high temperature treatment, such as sin- tering, is necessary to have adequate diffusion and the formation of a true alloy. That of the second one is, the redueed compressibility (ability to obtain high green densities at low compaction pressures) caused by the increased strength and resistance to plastic deformation of the individual particles. However, for P/M forging the second approach has two major ad- vantages, namely (1) high compressibility is no longer a major consideration; the preforms will have relatively low densities and densification will be ac- complished by hot forging, rather than by cold die compaction used for conventional P/M structural parts requiring high densities; and (2) there are eco- nomic benefits associated with lower sintering tem- peratures which, when coupled with hot forging, can produce a metallurgicaly sound material without substantial diffusion of alloying elements. ‘Thus, it is reasonable to expect that ferrous alloy preforms will be made from high purity, prealloyed atomized powders with a relatively large averageparticle size. Special grades of powders, including pure iron, designed especially for forging preforms, will probably be developed soon by powder pro- ducers. ‘Transforming a mass of loose powder into a green compact with sufficient strength to allow handling has traditionally been accomplished by pressure com paction in a rigid die, In the produetion of conven- tional structural P/M parts, compaction is used to control densification, shape, and to some extent, di- mensional tolerances. However, forging preforms will not necessitate high green densities or very close di- mensional control. There is still considerable debate regarding the extent of shaping of the preform (to be considered in detail in the next section). These differences promote the possible use of less common powder consolidation techniques instead of die com- action. Indeed, die compaction has several im- portant limitations. Uniaxial pressure application ‘and ejection of the compact from the die restricts compact height to diameter ratios and shapes, Powdered lubricants are usually mixed with metal powders to achieve sufficient lubrication for both compaction and ejection; they can lead to serious property degradation of the final product and in- creased costs related to lubricant removal during subsequent processing. Isostatic compaction is one alternative that is re- ceiving considerable attention, In this method rub- bery or flexible molds are filled with powder, sealed and then immersed in a fluid that is subsequently pressurized. In this manner pressure is applied quite uniformly on all or most of the surfaces of the pow- der mass. The mold is subsequently stripped off the green compact and either reused or discarded, More sophisticated systems make use of permanent tooling whereby the compact can be easily removed when the pressure is released. The chief advantages of isostatic compaction are that very complex shapes and large sizes can be produced. And in most cases admixed lubricants can be eliminated, The tooling usually can be made quickly and at low cost com- pared to rigid die tooling; this facilitates experi- ‘mental work and short runs. Traditionally, this tech- nique has not achieved widespread use for metal structural parts production (in contrast to billets and ingots, particularly for refractory metals) be- cause of lower compaction pressures, poorer mensional control and lower production rates as compared to die compaction. However, forging pre- forms essentially eliminate the first two disadvan- tages; and the third is being overcome by advances in equipment design, Additionally, this method tends to yield higher green strengths; this is important for some atomized prealloyed powders, Slip casting is another powder consolidation ‘method that is being studied for preform applications. In this case a slurry containing the powder and various chemical additives is poured into a permeable mold through which most of the liquid can pass, No pressure is applied. Low density compacts result, and these must be treated to remove residual mois- ture and the chemical additions. The technique is particularly attractive for the production of complex shapes made from powders with poor compressibility and green strength for pressure compaction. This approach is being studied for spherical, prealloyed atomized powders of various types of superalloys, as ‘well as die and isostatic compaction," When considering the normal powder metallurgy process it is customary to sinter green compacts in a suitable protective atmosphere. For powder forging it is possible to deviate significantly from the tradi- tional scheme, Instead of sintering the green com- pacts, the preforms, in a normal manner, one may envisage combining sintering and forging preheating (or soaking). There are obvious economic advantages to combining the two thermal treatments; however, there are a number of technical problems that still remain to be solved. First, consider a conventional sintering scheme. Continuous, mesh-belt sintering furnaces are gen- erally used for structural parts. These contain a pre- heating zone for lubricant burnoff, a hot zone for sintering, and a cooling zone. Two types of preforms could lead to desired or mandatory changes in fur- nace design. Preforms made by a compaction tech- nique not requiring admixed lubrication would per- mit a major reduction in the size of the first furnace zone; it would only have to heat the compacts at a reasonable rate. A more serious problem is that many potential preforms would be quite large and heavy in comparison to contemporary P/M parts, This could lead to: larger furnaces to accomplish lubricant burnoff, heating and cooling; longer times in the furnace; and either reductions in furnace loading because of insufficient belt strength, or the use of different types of furnaces, such as pusher types. If sintering is carried out at the forging site, then an efficient procedure would be to cool the preforms only to the forging preheat temperature, rather than to one near ambient temperature. This approach ‘would simply necessitate redesigning the cooling zone and placing the furnace near the forging equipment. ‘The productivity of both the furnace and the forging equipment would have to be matched, or with a suitable plant layout one furnace could supply several forging stations. ‘The process can be improved still more if the sintering temperature is lowered, and approaches that required for forging. For example, sintering of ferrous materials is normally done at '2050-2100°F (1120-1150°C), whereas work to date indicates that forging of ferrous P/M preforms can be done at 300- 700°F lower, Either short continuous furnaces or batch furnaces (possibly conventional forging pre- hheat furnaces) could then be utilized. Probably the single most important factor in allowing this redue- tion in sintering temperature would be the use of prealloyed powders, considered earlier, and the use of suitable atmospheres. The latter is particularly im- portant for carbon steels, for which atmospheres SEPTEMBER. 1970, JOURNAL OF METALS—23having desired carburizing potential could facilitate the use of lower temperatures and, possibly, the elimination of graphite powder in the original powder ‘The advent of powder forging has increased in- terest in totally different approaches to sintering. The use of induction heating for ferrous materials is being studied for sintering-preheating applications." Potential advantages include: the attainment of very high temperatures virtually impossible to achieve economically with conventional furnaces (of particu- lar interest for blended elemental powder approach for complex alloys); very short processing times; reduction in floor space requirements; reduction in atmosphere requirements; and reduction in capital ‘equipment, operating, and maintenance costs. PREFORM DESIGN AND CONTROL Perhaps the greatest challenge is preform design which is closely associated with the forging step. A. fundamental consideration is the shape of the pre- form. It must be firmly recognized that for P/M pre~ forms the forging step has the major function of material densification in addition to controlling shape and dimensions. There are those who argue that a relatively unshaped or “slug” type of preform should be used. The reduced strength of the porous material could conceivably permit a simpler forging operation (considered in detail later) as compared to conven- tional practice, although considerable material flow ‘would be required to achieve the shape. The alterna- tive approach, that appears to offer greater potential, is to use an appropriately well shaped preform. Densification would still necessitate some material flow; however, the forging step and the necessary tooling would. be simplified substantially. Dimen- sional control may also be improved. An example of a shaped preform and the resultant forging is shown in Fig, 3. The degree of shaping introduced by the origi- nal preform compaction step must be optimized for the specific part and preform fabrication and forging methods employed. Considerable shape can be eco- nomically introduced by both die and isostatie com- action. Preform density must also be critically evaluated. A major advantage of powder forging is the vastly improved forgeability of the P/M preform as com- pared to similar materials at full density. This im- provement is directly related to the presence of porosity and the concomitant reduction in strength of the preform. In addition, preform fabrication can be more economical by specifying relatively low densities. The yet unanswered question is the possible problems that may arise with relatively large amounts of interconnected porosity in the preform, ‘The two most serious ones appear to be internal oxidation and, for carbon steels, decarburization prior to and during forging. Both of these, however, probably can be eliminated by the use of proper sin- tering-preheating atmospheres and well-shaped pre- forms. 24—JOURNAL OF METALS, SEPTEMBER 1970 The sintering-preheating atmosphere can be re~ tained in the preform porosity upon its removal from the furnace. The atmosphere should have both oxide reducing and, if necessary, a proper carbon potential. If the preform is forged quickly the atmo- sphere can protect the interior of the material, as well as the surface, as it emerges from the interior and forms a protective envelope In addition to fast transfer from the furnace to the forging equipment, a shaped preform would facilitate the forging per se. ‘The usual objective is a one-step (one die or impres sion) forging, This, coupled with the expected lower forging temperatures (also related to increased forgeability) should minimize or eliminate these po- tential problems. At present it appears that pre~ forms with 15-80 vol. porosity will be acceptable, If a powder contains large amounts of fine particles, (minus 325 mesh), the case for some nonferrous types, it is possible to have substantial amounts of closed or isolated rather than interconnected porosity. This would normally promote material contamina~ tion and, possibly, lower forgeability because of the greater difficulty in densification, ‘The degree of preform shape and density is closely linked to the material's response to hot forging. A marked difference for porous preforms is that much of the apparent strain or movement of the material during forging (assisting die filling) is related to densification and not plastic deformation of the solid metal. The reduction in pore volume Ieads to an overall reduction in volume for the workpiece. The stresses required to achieve substantial densifica~ tion at elevated temperatures are relatively low. However, once at 95-98% of theoretical density the material becomes quite resistant to further densifica- tion (an apparent work-hardening). At the end of the forging stroke considerable pressure would have to be applied in order to achieve complete densifiea- tion. This would be accompanied by substantial plas- tic deformation of the metal. The optimum situation is to apply only as much pressure as required to achieve full density and complete die-flling to achieve the final shape, dimensions and properties, Flashless forgings are the usual objective with the preform approach; this will be considered in the next section. For powder forging to succeed, considerable atten- tion must be given to preform control. If sintering is combined with preheating, then adequate quality control must be emphasized after the initial compac- tion step, The weight of the preform will probably be the most eritieal factor. It may have to be con- trolled to within +1° to achieve the desired dimen- sional control, densification, and elimination of flash. Preform density must be adequately controlled to ‘minimize variations in density (forgeability) and dimensions of the hot preform. The latter is particu- larly important with respect to rapid insertion of the hot preform into the die.Fig, 3lllustration of shoped titanium P/M preform, let, ond os forged trunnion Foro jet engine, right" FORGING SEQUENCE Fis, 4Compariton of forging vequences for contentional technique sartng with bor stock and powder metollurgy technique starting with preforms. FORGING PRACTICE Fundamentally powder forging should be a very simple process, as illustrated in Fig. 4. With adequate preform porosity (forgeability) and shape only one application of force need be applied. Some technical aspeets of the forging step will now be considered, A major difference will be forging tooling. In addi- tion to an obvious reduction in the number of dies required, the type of tooling will probably be markedly different than currently used matched im- pression type dies with flash openings. Most of the current work is with “insertion” or “entry” tooling; that is, the moving ram carries an upper tool that enters die cavity, and then contacts the hot pre- form, This scheme is analogous to conventional-die powder compaction tooling, and is an obvious con- sequence of the greater activity within the powder ‘metallurgy industry as compared to the forging one. ‘This approach also lends itself to the use of a care- fully controlled preform and the elimination of flash. ‘There are, of course, some restrictions on part shape with this type of tooling. Also, adequate drafts must be used to allow ejection, with some type of lower tool motion, or hand removal of the forging. In general, problems associated with tooling, par- ticularly materials of construction and life, will be alleviated by the lower temperatures and, possibly, pressures associated with powder forging. Although there may be less problems associated with die 1u- brication, current practices, including die heating, are likely to be continued. Relatively small clearances between the moving tooling and the die will be re- quired to eliminate metal extrusion and flash forma~ tion, Proper die filling is likely to be a major prob- lem, Preform densification during forging is a form of work-hardening, Those regions of the preform near the surfaces initially in contact with the tool- ing will densify first and are likely to be difficult to flow relative to the tooling, Thus, early in the stroke fa barreling effect may occur, Subsequently, when friction is overcome these same regions may be the first to undergo true plastic deformation, and an in- verse barreling may occur. Only with sufficient pres- sures and proper preform and die design will com- plete densification and die filling be insured. “Dead- metal zones,” associated with regions of little or no plastie deformation," may be replaced by “low dens- ity zones’ as a type of forging defect. These will most likely be in the central regions of the larger size forgings, particularly when the maximum pressure isonly marginally adequate ‘The present types of forging equipment are likely to be used for P/M forging. Much of the current work. ig being done with presses rather than hammers be- cause the former are available in powder metallurgy operations, There have been some problems with insufficient pressures leading to incomplete densifica~ tion." Fundamentally it may be best to have a rapid Initial application of force to the preform followed by a relatively slow, high pressure squeezing action. ‘This sequence would take advantage of the original weakness of the preform prior to “working” the ma~ terial to its final density and shape. The effects of rate of pressure application on forgeability, die filling, tool life, and densifieation require investigation. High energy rate forming (HERF) techniques are also being evaluated for P/M forging, SEPTEMBER 1970, JOURNAL OF METALS—25Some data illustrating in a limited manner what can take place during P/M forging are given in Table I. Although the work was done some time ago under the guise of “hot pressing of iron powder,” it more closely resembles P/M forging, STRUCTURE, PROPERTIES AND EVALUATION’ OF P/M FORGINGS ‘The problem of achieving complete densification during forging has already been alluded to. There are several important aspects of this. The sharp in- crease in properties as full density is approached, as illustrated in Fig. 1, can be the basis for several of these problems. Very small departures from full density can signify large reductions in resultant properties. Whatever the intended density of the forging, and it usually will be 100% of theoretical, allowable deviations for commercial practice must be very small—perhaps fractions of a percent. It should not be overlooked that there may be many cases where it is prudent to design a P/M forging fon the basis of a density in the 95-98% theoretical range, if property specifications are met, ‘The consequences of small differences in density place great emphasis on density measurement. Two problems arise, First, the accuracy and reproduei- bility of the measurement technique must be of the highest caliber. Second, density variations within a part must be considered, and probably evaluated by sectioning techniques. Small amounts of residual porosity in critical load bearing regions could lead to catastrophic failures, To emphasize the amount of porosity in the material, density shall be expressed fas a percent of theoretical density rather than in units, such as g/cc. However, a practical problem is the selection of the full density value. Differences in alloy composition and impurity content for P/M. materials compared to cast and wrought forms can lead to errors. It is not uncommon to calculate a density value that appears to be greater than 100% of theoretical. Also, it should be remembered that wrought and, especially, east materials often contain small amount of porosity which is reflected in some experimental values. Nondestructive testing techniques should be de- veloped for density control, Elastic properties are very sensitive to density variations, and sonic mea- surement techniques have been used successfully.” Variations within a forging should be detectable. Pore shape variations can be extremely important; metallographic examinations may be required to elucidate this feature. ‘The basic nature of the metallurgical structure of P/M forgings is likely to be quite different than that of conventional forgings. The four most important areas are: homogeneity of structure; grain size; di- rectionality of structure; and impurity content’ and form, Prealloyed or mixtures of elemental powders will normally lead to very homogeneous structures. The various types of gross segregation present in cast ingots and eventually wrought forms and forgings, 26—JOURNAL OF METALS, SEPTEMBER 1970 ication of iron preforms” Eleetolie rn, powder die pested at 20 tat te rectanguly com- eee pete ot if el dees ake othe Ie plent cs o emperatas and tine at peau a slaves such as banding, will not be present in P/M forgings. ‘This should improve most properties. ‘The relatively small particle sizes in the initial powder and limited grain growth during sintering- preheating and forging should lead to smaller grain sizes than in conventional forgings. At low tempera ‘tures this normally is advantageous for strength and duetility, whereas for materials, such as superalloys, used at elevated temperatures this is a serious dis- advantage. Considerable plastic flow is associated with con- ventional forging. This is usually evidenced by a highly oriented grain structure and distinct flow lines. This leads to highly anisotropic properties. Often, high strength in one direction is considered an advantage; however, reduced properties in other directions can lead to problems. As pointed out earlier the amount of true solid plastic strain in P/M forging is quite limited. Thus, there should be a more equiaxed structure and much greater uniform- ity of properties in all directions. For many materials the impurity content is likely to be less in a P/M forging. Perhaps, more probable is a difference in the type and form of the impuri For example, in ferrous forgings there may be fewer inclusions but more dissolved gases. Much depends fon the condition of the original powder and the sintering-preheating atmosphere. If, indeed, there is a more isotropic structure in P/M forgings, property determination is simplified somewhat. However, more study is required to vali~ date this point. Exact test procedures may require more consideration. For example, impact testing of conventional sintered materials is done with un- notched bars because of the presence of porosity, However, P/M forgings should be evaluated with standard notched bars. ‘Two other practical problems remain to be fully evaluated, Some data being obtained for P/M forg- ings actually pertain to preforms forged without re- straint (upsetting). Consequently, there may be dif- ferences in structure and properties. Additionally,Table Il_Properties of ferrous P/M forgings" wy, Dievforeed Proform) TL 0 as eee ars acted ba oy SST ce vss non“ SEE tithe ote a econo Soh test specimens are usually machined from a forging. It should be recognized that the true external sur- faces of the forging may be quite different than the Interior. There may be a more deformed structure, less porosity, and a region of greater oxidation or decarburization, Thus, the properties, particularly fatigue strength, of ‘the actual forging may be markedly different. Metallographic examination is required to delineate such surface features. Table I contains some mechanical property data for some ferrous P/M forgings. At or near full density such materials have properties similar to those of conventional forgings of the same materials. Sim- ilarly, it has been shown, for P/M forged 4840 steel at full density, that the Jominy end quench harden- ability curve is identical with that obtained on fine rained wrought material.” Some of the data in Table II illustrate little effect on properties from the use of lamp-black coatings to facilitate forging, or the presence of sulphide inclusions to improve ma- chinability. For the 4650 steel the effect of 2° poros- ity can also be seen; the reduction in ductility is much greater than that for strength. Similar data for nonferrous materials are given in ‘Table Il, In this case comparative data are given for either sintered, cast or conventional forged ma- terials. Here too the potent effect of porosity on ductility can be observed. In most cases the proper~ ties of fully dense P/M forgings are similar to those of conventional forgings with approximately the same level of impurities. Higher gas contents in the former sometimes lead to greater strengths but lower ductilities. An important point is that some very ‘complex nonferrous alloys now considered unforge~ able can be P/M forged. ‘Table IIProperties of nonferrous materials pes SE Se ECONOMIC BENEFITS In a recent survey” concerning P/M forging the question was asked: “For any application, present or future, indicate why you fee] P/M forgings should be used ‘to replace parts now made by another method.” The overwhelming majority, 84.1", men- tioned cost as a main consideration, Considering the simplicity of the process, as shown in Fig. 4, this viewpoint is expected for the forging industry or companies that consume parts made by a variety of techniques. The most important reasons for this reduction in cost can he summarized as follows: 1) reduced forging steps—ideally one blow in one die; 2) reduced forging pressure allowing the use of smaller forges; 3) reduced forging temperatures making preheat- ing less costly; 4) reduced tool costs due to above factors: 5) reduction in skilled forging personnel; 6) reduction in serap due to elimination of flash and secondary machining operations; 7) reduction or elimination of various secondary operations due to elimination of flash, improved dimensional control and improved surface fin ish; 8) improved reliability, less rejections related to fewer and more simplified operations and ‘greater consisteney of forging stock (preforms) Inherent in this evaluation is the fact that preform manufacture when coupled with the above factors represents a reasonable fraction of the total cost Indeed, from @ powder metallurgy viewpoint pre- form manufacture is considerably less costly than P/M finished products. ‘There are, of course, many engineering factors that can be cited for the use of P/M forging, leading to improved properties and performance. Chief SEPTEMBER 1970, JOURNAL OF METALS—27among these are: closer tolerances, improved me- chanical properties and greater shape complexity. Some examples of conventional forgings for auto- motive applications made by the P/M preform ap- proach are shown in Figs. 5 and 6. Although there are some ferrous and nonferrous P/M forgings in use today, the significant breakthrough awaits adoption within the automotive field. This is expected shortly. Also included in Fig. 6 is an example of the use of a composite bimetallic P/M preform. This concept and the introduction of entirely new alloys achievable only with the use of P/M preforms can be the basis, for entirely new and expanded forging markets. An example of a complex P/M forging made in Japan is shown in Fig. 7. Evaluating P/M forging from the perspective of the powder metallurgy industry is also necessary. ‘The greater activity in this industry as compared to the forging one is based primarily on potential new markets. Fundamentally, the most important factor is the high density levels and concomitant improved properties that would allow the P/M fabri- cator to compete with castings and forgings, particu- larly for large sizes. Even if only the preforms were ‘manufactured, it would represent new markets, Also of importance is the possible simplification of alloy compositions and processing, particularly heat treat~ ing, that would result from replacing conventional sintered materials with P/M forgings. There would be considerable savings in capital equipment costs because of the less complex compaction and sinter- ing-preheating equipment required. COMMERCIAL EXPLOITATION ‘The present uncertainty of the future of P/M forg- ing is related to a number of factors. First, there is the intriguing question of who will exploit this process. Four distinct groups are active: P/M fabri- ators, forging companies, diversified in-plant opera- tions (notably the automotive companies) and powder manufacturers, The latter have the most to gain. Whoever uses the process, powder producers will benefit, Indeed, considering the widespread in- creases in both ferrous and nonferrous powder production capacities, their future is virtually de- ‘28—JOURNAL OF METALS, SEPTEMBER 1970 Fig, S—Automobile engine connecting 10d; forged condition, left, ond finished condi- tion, including both sleeve and on cil im pregrated becting, right pendent on the adoption of this approach within the next few years, Ferrous P/M preforms could easily double or triple the consumption of ferrous powders. Diversified in-plant operations have the advantages of: Integrated technical know-how in applications, powder metallurgy and forging; greater resourees for development work; and the economic leverage associated with high volume production. Although P/M fabricators have considerable incen- tives and the aid of powder producers, they usually lack adequate expertise in the art and science of forging, It is somewhat surprising that the forging industry, particularly ferrous oriented companies, has not expressed greater interest in this field. From forms: top, cooted idler shots; bottom, sectioned valves showing compete onstruction resulting from use of bimetallic preform =Zofia 6 67 6 8 HO as tool made by powder forging” @ purely technical viewpoint the most efficient and economical use of P/M forging will probably depend more on the optimum use of the forging step rather than on preform manufacture or sintering-preheat- ing. The introduction of preform manufacturing and sintering capabilities into existing forging operations is technically and economically feasible and reason- able, The purchase of sintered preforms from an outside source should also be a competitive approach with many products. The reduction or elimination of equipment and personnel currently associated with preparation of the forging stock should not be over- looked. Acquisitions among forging and P/M com- panies are likely. ‘The image appears to have been well formed al- ready. In the survey referred to earlier the question was asked: “If you were in need of a P/M forging, would you expect to: Make it yourself?—Purchase from a P/M fabricator?—Purchase from a supplier of forgings?—Check both P/M fabricator and sup~ plier of forgings?” The responses were 8.1%, 64.9%, 12.6% and 14.4%, respectively. Clearly, P/M fabrica- tors are recognized as the leaders in this area. Naturally, there are competitive techniques, Con- siderable activity has already occurred in the devel- opment of cast preforms. Advances continue to be made in alloying and processing for sintered ma~ terials, many of which can now compete with forg- ings. And there is likely to be some developments in forging and casting technology mitigating some of the advantages noted earlier. There is little question concerning the need for substantial amounts of hard data on all aspects of P/M forging. The lack of disseminated information, necessary for proper decision making, is partially responsible for the reluctance of many companies to pursue this approach. Industry sponsored research and development work at universities and indepen- dent laboratories is needed. Lastly, it should be noted that P/M forging offers great potential for the less technologically developed nations. I simplifies both forging and powder metal- lurgy operations. Whereas new powder metallurgy operations are difficult to establish because of the need for highly knowledgeable and trained personnel and complex equipment, forging operations already in existence could be used as a base for efficient P/M forging endeavors. The basic simplicity of the process, particularly the reduction in the quantity and complexity of tooling, make it suitable for low to moderate levels of production. CONCLUSIONS 1, The advantages of using P/M preforms will lead to reduced costs for consumers, and to new and ex- panded markets for P/M and forging companies. This growth is being spearheaded by automotive applica~ tions of ferrous materials. 2, The preform concept offers expanded latitude for component design, materials selection, powder consolidation methods, and forging practice. How- ever, to attain the highest possible levels of tough- ness and ductility, proper choices must be made to achieve fully dense forgings free from deleterious impurities. 3. To accelerate the commercial acceptance and exploitation of the preform concept, more data on the entire process must be generated and dissemni- nated, REFERENCES “doer J 8: Die Re) Rete tage we nee Bight ro gfe PM ano via ad Praca, Rll Bok’ orgs New York, i nok, iRinaws'R, “anew Developments in igh Bena. High, Com. renbiuy Fern Powders, ARTA Tech: Paper EMOD 65,196 Rely. Wks Pubrcstr Proven termined by T-6ALAV Ps Machine Design Rear Actioh Report on Ref, 8, Oct. 1968 2Gainon: BBs Nene Deanne > Revue Sioa Matera, Acknowledgment SEPTEMBER 1970, JOURNAL OF METALS—29