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Chris Schade
Hoeganaes Corporation
Cinnaminson, NJ 08077
John Schaberl
Ancor Specialties
Ridgway, PA 15853
Alan Lawley
Drexel University
Philadelphia, PA 19104
ABSTRACT
INTRODUCTION
MPIF Standard 351 lists the most common grades of stainless steel used by PM parts
manufacturers. These include austenitic grades such as 303L, 304L and 316L, and ferritic
grades such as 409L, 410L, 430L and 434L. However, with the continued growth of
stainless steel there exists many opportunities for specialized stainless steel grades not
covered by MPIF Standard 35. These include applications requiring enhanced physical
properties, corrosion resistance, weldability and machinability. There are additional
grades covered by the American Iron and Steel Institute (AISI) that can be manufactured
by conventional press and sinter powder metallurgy (PM), Figure 1. The AISI
designation for these alloys is well known with the number series 200 and 300 referring
to austenitic stainless steels and the 400 series covering the ferritic and martensitic
stainless steels. Letter designations attached to the end of the number series indicate
modifications to the composition.2 Many societies such as the Society for Automotive
Engineers (SAE) and the American Society for Testing and Materials (ASTM) use the
AISI specification with the latter adding physical property specifications.3 SAE and
ASTM have worked together to create the unified numbering system (UNS) for metals
and alloys, which is recognized globally and can be used as a cross-reference
internationally. 4 Other references covering both wrought and cast grades of stainless steel
are available.5-6
The powders used in this study were produced by water atomization with a typical
particle size (100 w/o) <150 µm (–100 mesh) and with 38 to 48 w/o <45 µm (-325
mesh). All the alloying elements were prealloyed into the melt prior to atomization,
unless otherwise noted. Admixed copper, molybdenum and nickel powders were used to
make some compositions and are so designated in the tables of chemical composition.
The stainless powders were mixed with 0.75 w/o Acrawax C lubricant. Samples for
transverse rupture (TR) and tensile testing were compacted uniaxially at 690 MPa (50
tsi). All the test pieces were sintered in a high temperature Abbott continuous-belt
furnace at 1260 °C (2300 °F) for 45 min in hydrogen with a dewpoint of –40 oC (-40 °F),
unless otherwise noted.
Prior to mechanical testing, green and sintered density, dimensional change (DC), and
apparent hardness, were determined on the tensile and TR samples. Five tensile
specimens and five TR specimens were tested for each composition. The densities of the
green and sintered steels were determined in accordance with MPIF Standard 42 and
tensile testing followed MPIF Standard 10. Impact energy specimens were tested in
accordance with MPIF Standard 40. Apparent hardness measurements were conducted
on tensile, TR and impact specimens, following MPIF Standard 43.
Rotating bending fatigue (RBF) specimens were machined from test blanks that were
pressed at 690 MPa (50 tsi) and sintered at 1260 oC (2300 oF). The dimensions of the test
blanks were 12.7 mm x 12.7 mm x 100 mm. RBF tests were performed using rotational
speeds in the range of 7,000-8000 rpm at R equal -1 using four fatigue machines
simultaneously. Thirty specimens were tested for each alloy composition, utilizing the
staircase method to determine the 50% survival limit and the 90% survival limit for 107
cycles (MPIF Standard 56).
Salt spray testing on TR bars was performed in accordance with ASTM Standard B 117-
03. Five TR bars per alloy (prepared as previously described) were tested. The percent
area of the bars covered by red rust was recorded as a function of time. The level of
corrosion was documented photographically.
RESULTS AND DISCUSSION
For PM applications, the ferritic stainless steels are by far the most widely used grades,
reflecting their application in the automotive industry. Examples are ABS sensor rings
and muffler exhaust flanges. Chromium is the major alloy constituent of the ferritic
grades along with minor additions of other ferrite stabilizers such as silicon and niobium
(Table I). In general, the 400 series, ferritic stainless steels contain 11 to 27 w/o Cr, are
magnetic, have moderate ductlity and corrosion resistance and are relatively weak at high
temperatures.7-8 In order to form the passive oxide layer a minimum of about 11 w/o Cr is
required.
AISI UNS C S P Si Cr Ni Cu Mn Mo Nb
1 0.03 .030 .040 1.0 10.5 .50 .50 1.0 .50 .40
409L S40940
Max. Max. Max. Max. 11.7 Max. Max. Max. Max. .60
0.03 .030 .040 1.0 11.5 .50 .50 1.0 .50
410L1 S41000 ---
Max. Max. Max. Max. 13.0 Max. Max. Max. Max.
0.03 .150 .040 1.0 11.5 .50 .50 1.0 .50
416L S41603 ---
Max. .300 Max. Max. 13.0 Max. Max. Max. Max.
0.12 .030 .040 1.0 16.0 .50 .50 1.0 .50
430L1 S43000 ---
Max. Max. Max. Max. 18.0 Max. Max. Max. Max.
0.03 .030 .040 1.0 16.0 .50 .50 1.0 0.75
434L1 S43400 ---
Max. Max. Max. Max. 18.0 Max. Max. Max. 1.25
0.03 .030 .040 1.0 16.0 .50 .50 1.0 0.75 .40
436 S43600
Max. Max. Max. Max. 18.0 Max. Max. Max. 1.25 .60
0.03 .030 .040 1.0 16.0 .50 .50 1.0 .50 .40
439 S43035
Max. Max. Max. Max. 18.0 Max. Max. Max. Max. .60
0.03 .030 .040 1.0 16.0 .50 .50 1.0 .50
441 S44100 1.00
Max. Max. Max. Max. 18.0 Max. Max. Max. Max.
0.03 .030 .040 1.0 23.0 1.0 .50 1.0
446 S44600 --- ---
Max. Max. Max. Max. 27.0 Max. Max. Max.
0.03 .030 .040 1.0 25.0 1.0 .50 1.0 0.75 .05
446 S44626
Max. Max. Max. Max. 27.5 Max. Max. Max. 1.50 .20
1
Covered by MPIF Standard 35
The early use of these grades was limited by the amount of carbon and nitrogen in the
alloys. With higher levels of carbon and nitrogen, the ductile to brittle transition can
occur at low temperatures. However, with the advent of argon-oxygen-decarburization
(AOD), lower values of nitrogen and carbon have been acheieved and the ductility of
these grades has been greatly enhanced.9 The effect of carbon and nitrogen can furthur be
reduced by the addition of niobium which combines with the interstitial elements to
prevent sensitization. Niobium is also a ferrite stabilizer which helps to prevent the
formation of martensite in the alloys.
In general, the oxidation resistance and mechancial properties (Table II) increase as the
chromium level increases. The addition of other alloying elements to the base
compositions can enhance certain properties. For example, in the case of 434L, when
molybdenum is added, the resistance of the alloy to corrosion by road salt is increased.
Niobium is added to several stainless steel grades to prevent the formation of chromium
carbides which leads to intergranular corrosion (409L,436 and 439). This is particularly
important when welding ferritic stainless steels, since the formation of chromium
carbides is rapid and difficult to avoid. Sulfur can be added to enhance the machinability
of ferritic stainless steels. In AISI 416L, sulfur is prealloyed prior to atomization, and the
element combines with manganese during solidification to form managnese sulfides that
assist in machining. This technique has been used in the PM grade of 303L for many
years.
20
Hastelloy X
Super Ferritic
310L
15 441
409Cb
% of Initial Weight
10
0
800 850 900 950 1000 1050 1100 1150 1200
o
Temperature ( C)
Figure 2. Weight gain (in air) as a function of temperature for selected oxidation resistant alloys.
Austenitic Stainless Steels
The AISI 300 austenitic series stainless steels contain nickel and chromium and have
excellent corrosion resistance in diverse environments. The properties of austenite are
generally described as nonmagnetic, with a relatively low yield strength, high ductility
and excellent impact toughness. Austenitic stainless steels behave in a manner similar to
that of low carbon steels but with enhanced high temperature strength and oxidation
resistance. Depending on chemical composition, these stainless steels can resist scaling
up to 1095 oC (2000 oF). Conversely, austenitic stainless steels can be used in low
temperature applications where their high toughness levels are compatible with cryogenic
applications.
Based on Table III, there exists a wide range of 300 series stainless steels suitable for a
variety of applications. This table also includes stainless steel grades commonly used by
the PM industry and detailed in MPIF Standard 35, namely 303L, 304L and 316L. With
the increased use of PM stainless parts an exploration of other grades listed in Table III
would appear to be timely.
AISI UNS C S Si Cr Ni Cu Mo Nb
0.03 .030 2.0 17.0 8.0 .50 .50
302B S30215 ---
Max. Max. 3.0 19.0 10.0 Max. Max.
0.03 .150 1.0 17.0 8.0 .50 .50
303L1 S30300 ---
Max. .300 Max. 19.0 10.0 Max. Max.
0.03 .030 1.0 17.0 8.0 .50 .50
304L1 S30403 ---
Max. Max. Max. 19.0 10.0 Max. Max.
0.12 .030 1.0 17.0 8.0 3.0 .50
304Cu S30430 ---
Max. Max. Max. 19.0 10.0 4.0 Max.
0.03 .030 1.0 22.0 12.0 .50 .50 .40
309Cb S30940
Max. Max. Max. 24.0 16.0 Max. Max. .60
0.03 .030 1.5 24.0 19.0 .50 .50
310S S31008 ---
Max. Max. Max. 26.0 22.0 Max. Max.
0.03 .030 1.0 16.0 10.0 .50 2.00
316L1 S31603 ---
Max. Max. Max. 18.0 14.0 Max. 3.00
0.03 .030 1.0 16.0 10.0 .50 2.00 .40
316Cb S31640
Max. Max. Max. 18.0 14.0 Max. 3.00 .60
0.03 .030 1.0 18.0 11.0 .50 3.00
317L S31703 ---
Max. Max. Max. 20.0 15.0 Max. 4.00
0.03 .030 1.0 17.0 9.0 .50 .50 .40
321L S32100
Max. Max. Max. 19.0 12.0 Max. Max. .60
0.02 .030 1.0 19.0 23.0 1.0 4.0
904L N08904 ---
Max. Max. Max. 23.0 28.0 2.0 5.0
1
Covered by MPIF Standard 35
There is a growing need to weld PM austenitic stainless steel parts to other structures. In
doing so the normal grades of stainless steel (304L and 316L) are susceptible to
sensitization, particularly in areas adjacent to the weld. Sensitization is the process by
which chromium combines with carbon to form chromium carbides. The chromium is
removed from areas close to the grain boundaries and leaves these areas depleted of
chromium, with attendant susceptibility to intergranular corrosion. The formation of
chromium carbides is enhanced by temperature and generally occurs in austenitic
stainless steels at temperatures between 480 oC and 815 oC (900 oF and 1500 oF). The
cooling rate resulting from the welding process is generally slow which increases the
likelihood of chromium carbide formation. Increased carbon levels due to insufficient
lubricant burn-off can also increase the chance of sensitization. In order to avoid
postweld heat-treatment, stabilized grades of austenitic stainless steels have been
developed.
Other alloying elements, such as molybdenum, can be added to the austenitic stainless
steels to improve corrosion resistance. Molybdenum, when added at levels between 2
w/o and 4 w/o improves resistance to oxidation, pitting and crevice corrosion. The
addition of molybdenum also tends to improve both room and high temperature
properties such as tensile strength and creep. The mechanical properties of AISI 317L are
cited in Table IV and the corrosion resistance is illustrated in Figure 3. Currently PM
fabricators sinter austenitic grades in a hydrogen/nitrogen atmosphere to increase strength
(MPIF Standard 35: grades SS-304N and SS-316N). In so doing, significant chromium
nitride formation occurs, which is detrimental to the overall corrosion resistance of the
alloy. The addition of molybdenum is beneficial if both corrosion resistance and strength
are required.
(a) (b) (c)
Figure 3. Representative appearance of salt spray specimens: (a.) 304L, (b.) 316L, (c.) 317L.
More highly alloyed 300 series stainless steels are available that are designed to resist
oxidation at high temperatures while maintaining a high degree of tensile strength and
creep resistance. These alloys rely on the formation of the chromium oxide film for
protection from corrosion, but the additional nickel and silicon in these alloys helps to
form a more ductile scale, which increases its adherence to the base metal. The adherent
scale is particularly important when service conditions involve cyclic temperatures. The
properties of several of these PM grades (302B, 304L and 310L) are listed in Table IV
and the relative oxidation resistance of these grades is shown in Figure 4.
1.4
304L
1.2
302B
310L
1
% of Initial Weight
0.8
0.6
0.4
0.2
0
600 700 800 900 1000 1100 1200
o
Temperature ( C)
Martensitic steels in the 400 series are similar to the ferritic stainless steels in that they
contain chromium in the range of 11 w/o to 18 w/o but also contain other elements such
as nickel Table V. The martensitic stainless steels are magnetic and are generally used in
applications where hardness and/or wear resistance is required. When heat-treated they
can achieve high strength and when tempered, they can exhibit some ductility.
Essentially, these steels achieve mechanical properties comparable with those of a heat-
treatable low alloy steel but with enhanced corrosion resistance, although their corrosion
resistance is the lowest of any of the stainless steel categories. MPIF standard 35
recognizes SS-410-90HT as a martensitic alloy. For this grade, the sintering atmosphere
contains a high level of nitrogen, and the alloys form high temperature austenite, which
transforms to martensite on cooling.
AISI UNS C S Si Cr Ni Cu Mo Nb
0.03 .030 1.0 12.0 1.25 .50 .50
414M S41400 ---
Max. Max. Max. 15.0 2.50 Max. Max.
0.03 .030 1.0 12.0 4.0 1.5 1.5
414M S41426 ---
Max. Max. Max. 15.0 7.0 2.0 2.0
0.03 .030 1.0 11.5 3.5 .50 .5
415M S41500 ---
Max. Max. Max. 14.0 5.5 Max. 1.0
.15 .030 1.0 12.0 .50 .50 .50
420M S42000 ---
.30 Max. Max. 14.0 Max. Max. Max.
0.75 .030 1.0 16.0 .50 .50 .75
440BM S44003 ---
0.95 Max. Max. 18.0 Max. Max. Max.
0.95 .030 1.0 16.0 .50 .50 .75
440CM S44004 ---
1.20 Max. Max. 18.0 Max. Max. Max.
0.15 .030 1.5 11.5 1.0 3.0 .50
410LCu J91151 ---
Max. Max. Max. 14.0 Max. 5.0 Max.
M
Designates material made from a mix of a base powder and additives such as nickel, graphite, copper and
molybdenum.
Other AISI martensitic grades of stainless steel, such as 420,440A, 440B and 440C, can
be processed by adding graphite to ferritic grades of stainless steels such as 410L and
430L. Table VI gives the properties of 420L, 440B and 440C made by this approach.
The level of carbon added to the alloy dictates the mechanical properties of the
martensitic stainless steel. The higher the carbon content, the larger the extent of
chromium carbide formation, and the higher the strength and apparent hardness of the
alloy.
Table VI: Mechanical Properties of PM Martensitic Stainless Steels
Green Sintered Apparent
Impact TRS UTS 0.20% OFFSET Elongation
Density Density Hardness
AISI UNS ft.lbs.f (J) (g/cm3) (g/cm3) (ksi) (MPa) (HRB) (ksi) (MPa) (ksi) (MPa) (%)
410LCu J91151 13 17 6.43 6.84 249 1713 95 116 798 89 612 2.7
414 S41400 50 67 6.55 6.95 223 1534 90 98 674 75 516 3.7
414 S41426 21 28 6.62 7.00 209 1438 89 100 688 76 523 2.5
415M S41500 26 35 6.69 7.03 253 1741 96 108 743 80 550 2.9
415PA S41500 11 15 6.17 6.52 178 1225 83 98 674 73 502 2.3
420 S42000 24 32 6.68 6.86 172 1183 67 57 392 37 255 2.2
440B S44003 20 27 6.58 6.82 134 922 93 67 461 42 289 2.0
440B HT S44003 3 4 6.58 6.76 128 881 29/c 74 509 70 482 0.6
440C S44004 13 17 5.56 6.91 169 1163 94 79 544 61 420 2.2
440C HT S44004 3 4 5.56 6.90 155 1066 37/c 65 447 62 427 0.6
AISI 415M = Powder Mix, AISIPA = Prealloy.
(d) (e)
Figure 5. Representative appearance of salt spray specimens: (a.) 440B, (b.) 440C, (c.) 410Lcu,
(d.) super-martensitic admixed, (e.) super-martensitic prealloyed
As with other categories of stainless steels, super-martensitic stainless steels can be
formed by adding high levels of nickel, copper and molybdenum. For PM alloys the
prealloyed materials are usually low in compressibility but can exhibit superior corrosion
resistance due to their high alloy content.
Precipitation hardening stainless steels are not defined by their microstructure, but rather
by strengthening mechanism. These grades may have austenitic, semi-austenitic or
martensitic microstructures and can be hardened by aging at moderately elevated
temperatures, 480 oC to 620 oC (900 oF to 1150 oF). The strengthening effect is due to
the formation of intermetallic precipitates from elements such as copper or aluminum.
These alloys generally have high strength and high apparent hardness while exhibiting
superior corrosion resistance compared with martensitic stainless steels. Heat treatments
can be used to vary the properties of the alloys and involve short times (1 h) at
temperatures ranging from 480 oC to 620 oC (900 oF to 1150 oF). The aging treatment can
take place in either air or in nitrogen, depending on the surface appearance required.
However, these alloys should not be subjected to welding or in service temperatures
above the heat-treatment temperature because strength can be lost due to overaging.
The AISI designation for these alloys is the 600 series of stainless steels, but most are
more commonly known by their alloy name, for example, 15-5PH, 17-4PH and17-7PH.
The aluminum-containing precipitation hardening alloys are difficult to process by the
PM route due to their high affinity for nitride formation and the difficulty in reducing
aluminum oxide during sintering.
Table VII and VIII give the chemical compositions and mechanical properties of several
precipitation hardening alloys produced by conventional PM techniques. 17-4PH is a
martensitic grade in which ductility and toughness are generally higher than in the
carbon-containing martenstitc grades. The mechanical properties of 17-4PH can be
increased by 15% by aging at 538 oC (1000 oF) for 1 h. Applications for this alloy exist
in the food, chemical and aerospace industries.
AISI UNS C S Si Cr Ni Cu Mo Nb
0.03 .030 1.0 15.0 3.0 3.0 .50 .15
17-4PH S17400
Max. Max. Max. 17.0 5.0 5.0 Max. .45
.15 .030 1.0 12.0 .50 .50 .50
410LCu J91151 ---
.30 Max. Max. 14.0 Max. Max. Max.
0.07 .030 1.0 16.0 4.0 .50 2.50
633M S35000 ---
0.11 Max. Max. 17.0 5.0 Max. 3.25
Usage of the precipitation-hardening alloys is generally limited by the high cost of the
alloying elements. Recently, a lower cost PM precipitation hardening alloy has been
introduced based on UNS J91151 (a cast grade). 10 This alloy has only 13 w/o chromium
and utilizes the precipitation of copper to provide a low cost-high strength alloy with
moderate corrosion resistance. Table VIII shows that the mechanical properties approach
those of 17-4PH, while still maintaining a level of corrosion resistance that is better than
that of the high carbon martensitic grades.
AISI UNS C S Si Cr Ni Cu Mo Nb
0.08 .030 1.0 23.0 2.5 .50 1.00
Duplex- 329M S32900 ---
Max. Max. Max. 28.0 5.0 Max. 2.00
0.03 .030 1.0 21.0 4.5 3.0 2.50
Duplex- 2205 S32205 ---
Max. Max. Max. 23.0 6.5 5.0 3.50
.15 .030 1.0 10.5 1.50 .50 .50
Duracor/3Cr12 S41003 ---
.30 Max. Max. 12.5 Max. Max. Max.
Technically, duplex steels are stainless steels that contain two phases.3 Duplex stainless
steels are more-accurately defined as alloys containing a mixed microstructure of ferrite
and austenite. New alloys being developed that contain mixtures of ferrite and martensite
are generally termed dual-phase.11 Compositions of PM Duplex/Dual Phase stainless
steels are listed in Table IX. A major advantage of these stainless steel grades is that each
phase imparts improved properties to the alloy.
(a) (b)
Figure 6. Representative microstructures of (a) duplex stainless steel: (b) dual-phase stainless steel.
Duplex stainless steels are ferritic stainless steels (Figure 6(a)) containing chromium and
molybdenum to which austenite formers (primarily nickel) have been added to ensure
that austenite is present at room temperature. Duplex stainless steels have several
advantages over the austenitic grades including high strength, acceptable toughness, and
superior corrosion resistance, particularly to chloride stress corrosion cracking. The
mechanical properties of a duplex stainless steel (2205) are shown in Table X.
Dual phase stainless steels vary in composition but are generally non-austenitic (Figure
6(b)) and magnetic, containing 11 w/o Cr. The chemistry of the alloy is balanced by
ferrite formers and austenite formers. The austenite transforms to martensite upon cooling
resulting in a mixture of ferrite and martensite. Because of the low cost of the alloy it is
used as a replacement for plain carbon steels where increased corrosion resistance is
needed. The martensite in the alloy allows the material to be used in applications
requiring strength and wear resistance. The properties of a PM version of this stainless
steel (S41003) are cited in Table X.
Fatigue tests were performed on some of the high strength PM alloys developed. The results of
these tests,in terms of the 90% survival limit, are compared with those of other stainless steel
fatigue data by Shah et al. 12 in Figure 7. The latter study study compared the fatigue strength of
various stainless steels as a function of tensile strength.
Tensile Strength (MPa)
0 100 200 300 400 500 600 700 800 900
50 345
410LCu
420 Aged
Dual Phase
45
295
410LCu
40 Martensitic
409LNi 409LNi-HC 410HT
35 245
DUPLEX
17-4PH
409LE
30
195
430L
25 430N2
145
20 434L 434N
410L
15 95
10
45
5
0 -5
40 50 60 70 80 90 100 110 120 130 140
The excellent fatigue response of these alloys is attributed to their high tensile strength.
In general, fatigue crack propagation rates in PM steels are high and the fatigue limit is
dictated by crack initiation rather than by crack propagation. Resistance to crack
initiation increases as the tensile strength increases. All the PM alloys included in Figure
7 have high tensile strengths, and therefore high fatigue endurance limits. It appears that
the addition of copper, nickel, and molybdenum, results in harder martensite, which has a
positive effect on fatigue strength.
CONCLUSIONS
• Many AISI grades of stainless steel can be made via conventional water
atomization and press and sinter PM. These grades are not currently covered by
MPIF Standard 35, but provide a range of properties and corrosion resistance that
can lead to increased opportunities for PM parts producers.
• In ferritic grades, higher levels of chromium, niobium and sulfur can lead to
improved mechanical properties, corrosion resistance and machinability.
REFERENCES