Ei Metal Products, eRe ey er Deal Premixed Bronze Powders PMB series of prerrixed copper-tin-lubricant powders to provide low, medium and high growth control based on the needs of the bearings manufacturer. This ready-to-use family of copper-tin-ubricant premixes is specifically designed for the manufacture of oil-impregnated sintered bronze bearings and structural parts. A series of interrelated grades is available, each having controlled dimensional change properties, which enable the parts producer to obtain desired dimensions during sintering, while maintaining good rricrostructure, optimum strength and interconnected porosity for required oil content. Our PMB line is a graduated series of standard free-flowing bronze premixes composed of homogeneous mixtures of copper powder, tin powder and lubricant ready for direct use in the compacting press. These premixes are commonly referred to as 90/10 mixes (90% Copper, 10% Tin) and are available in six standard grades with related dimensional change characteristics. ‘The grade selection is based on the dimensional change desired as influenced by part density, part size or configuration and production sintering conditions. SCM Grades/Characteristics PMB-S Is the standard grade in this family. All other grades offer specific growth values relative to this grade PMB-O Lowest growth 90/10 mix designed to give 1.0% less growth than PMB-8 when sintered at 1530°F (832°C). PMB-3 Low growth 90/10 mix designed to give 0.5% less growth than PMB-8 when sintered at 1530°F (832°C). PMB-8 ‘The standard 90/10 mix designed to give nominal growth during sintering at 1530°F (832°C) when processing into P/M self lubricating bearings under normal production conditions. PMB-18 High growth 90/10 mix designed to give 1.0% more growth than PMB-8 when sintered at 1530°F (832°C)cu fate) elena eee Metal Powders™ PMB-23 Highest growth 90/10 mix designed to give 1.5% more growth than PMB-8 when sintered at 1530°F (832°C). PMB-302 Low Temperature Sinter Grade PMB-302 Bronze premix powder is a press ready bronze powder composed of mixtures of elemental copper and tin metal powders and lubricant. The 302 premix contains 3/4% added lubricant. The 302 grade is designed to be sintered at 1365°F to 1455°F (740°C to 790°C) to produce bearings with good ductility and high strength. The premixes are noted for consistent dimensional control, designed to give -0.9% racial shrinkage at 750°C (1380°F) and are suited for the manufacture of small bearings. The fine porosity and smooth surfaces minimize running noise ‘The above grades conform to the following industry and military standards for oilimpregnated sintered bronze bearings. MPIF SAE + CT-1000-K19 +» CT-1000-K26 © CT-1000-K37 ASTM + B438, Grade 1, Type | + B49, Grade 1, Type Il = 5255, Type | * B255, Type Il\g SCM METAL PRODUCT: ‘S, INC. wayne ig) 4-3 Powders for P/M BearingsSCM METAL PRODUCTS, INC. With over 60 years of manulacturing experience SOM Metal Products is a major producer of toth non-ferrous and ferrous powders and related metals products, Headquartered in Research Trangle Park. NC. we have our F&O facility and manufacturing plant on ste. To better serve ‘our customers, we oporate a second manufacturing facilty in Johnstown, PA dometown Plant esearch Tangle Park Facility Products produced include copper, tin, copper-base infitrating Oloetrolytic iron, stainloss stool and premixed bionze powders for PIM compacting as well as hard facing alloys, iron melt stock, braz: ing pesto, electrolytic iron powder, solder pastes and creams and dispersion strengthened copper for various other uses. While we serve many industries, we are a leader in PYM, and in the mid 1960's introduced the concept of stepped and related dimen. sional change grades of premixed bronze powders. These have Decome the Industly standards for use in the manufacture of P/M bronze bearings. Premixed Bronze Powders for P/M Bearings il impregnated self{ubricating bronze bearings were one of the arlest products ot powider metallurgy and remiain one of ine most important. They have the advantage over solid metal in that the porosity acts as a buil-in oil reservoir to supply lubrication. P/M bearings are widely used in fractional horsepower motors found in automobiles, home appliances and business machines as well as ether baaring applications. PIM bronze bearings are generally produced from mixtures of le ‘mental fn and copper powders. SCM Metal Products’ premixes are performance tested metal powder mixes designed fo fil he require= ments of the industry. The availabilty of a family of grades with related dimensional change characteristics enabies the bearing pro- ‘ducer to chaose a raw material which allows him to meet both the required material properties and the print dimensions without any ‘compromise in quality SCM bronze premixes contain reduced copper powders which FeSults in a pore structure gWving superior bearing performance. PIM bearings are manufactured to industry standards found in MPIF Standard 35, ASTM Standard B 438, and ISO 5755-1 7SCM Metal Products Bronze Premixes CM Netal Produets' premixed bronze grades have been designed to offer the following to the P/M bearing manufacturer. * A family of press-ready, 90/10 bronze powders with ubricant. + End the need to inventory many raw materials. inate multiple in-house mixing and powder testing. + Confident control of dimensional change during sintering. + Availabilty of consistent powder in 40,000 pound lots. + Abilty to produce bearings to MPIF, ASTM, ISO and SAE specifications. + Make bearing manufacturing more economical overall, Standard Grades PMBO 3.20. 628 640 (448) 70.50) PMBS am 628 G0 44) 00 PMBS 3 634 650 (448) $1.60 PMNS 32S. 536, 650 (445) +2.00 PuBis S280 537 560455) 1250 PuB23 328 638 670 (462) $3.00 When manufacturing with one set of tals the lower numbered PMB graces will give the growth needed to ronerly size amall Bearings, while the higher numbered PMS prades have more Bull-in growth, ‘To choose tho proper promix, a dimensional change tral run should first be made under production condl- tions with one of the PMB grades. Then, based on these test results, the final grade selection can be made with confidence employing the stepped grade interrelationship which is the heart of the SCM premixed bronze system. SCM grades are engineored so that when sintared at 1580°F (892°C), there is a progressive cimensional ‘change difference of 0.60% between graces. The dimensional change for each grade is shown as a band ‘over a range of temperatures.Powder Properties ‘The physical properties of the PM family of bronze powders have been designed for the parts producer. Powder apparent den- sity, flow rate and compacting properties are al levels which optimize performance during sintering. Grades are generally inter- changeable in a set of tools. These powsler properties are detailed in ths section, ‘The apparent densities cf PMB grades are ‘maintained at high levels for good fill charac- teat andthe ely te produce unio tan wall bearings. While each grade has a pecification which permits a range of 0.20 glem, the average ‘apparent density for the sik grades wil be between 3.20 and 3.25 glom?, The apparent density is determined using the Mall Flowmetor in accordance with standard test method, ASTM B 212 or MPIF 04, PMB powders are made to give the fastest flow withcut sac rifcing other properties. The average flow for the six grades, is between 30 and 38 seconds 'o assure powder with good fil properties. The fow is tasted using the Hall Flowmeter and 50 q ‘of powder with standard test methods, ASTM B 213 or MPIF 03. All grades are nominal -100 oF -150 mesh compacting premixes ‘with strict limit on the oversize particles, The -325 mesh content is closely controlled due to the influence of fines on apparent density, flow rate, compacting properties and dimensional change. This fracton also affects sintering characteristios and bearing performance. The average fines Traction of the PMB grades varies between 45 and 65% wih individual grades held 1a 15% tclorance. Sieve analysis is losted using Tyler sieves ‘on a Ro-Tap with 100 gram samples, folowing ASTM B 214 or MPIF 5 standard test methods,The compressibility of PMB grades permits beating densities to be reachod with compacting prossures of 10 to 18 181 (138 to 207 Nim’). The values for al six grades wil fall within the band shown, Compressibiity is determined on transverse rupture bars. pressed irom 15 9 of premix with movement and pressute pro- vided by both punches, following standard test methods, ASTM 301 or MPIF 45, The green strength of PMB powders is typically 550 to 750 psi (G8 to 5.2 Nmm') when compacted to commercal bearing densities. The results for all six PMB grades wil typically fall ‘within the band shown, Green strength is determined on trans- verse rupture bars pressed from 15 g of premix with movement and pressure provided by both punches, Standard test metn- ods, ASTM B 312 or MPIF 15 are followed. Power fow testingSintered Properties Dimensional control during sintering is key to the manulacture of quailty bearings. The PMB system allows the fabricator o select the grade which will give the desirod growth while maintaining a fully sintered structure. Results of dimensional change tests are ‘shown on the right for sintering tempera: tures between 1500 and 1560°F (816 to '849°C). These typical results form a series, ‘of nearly parallal curves with maximum growth at about 1530°F (832°C). The tam- erature of maximum growth is important because itis at this temperature that the alloying of the tin is complote, and an alpha bbronze microstructure for good strength ‘and ductility is developed. Graph values shown are based on test pieces pressed and sintered under dosely Controlled etandard conditions. to ascur® accuracy. The test specimen is a trans- verse rupture bar pressed to a green den- sity of 6.3 g/em’ and sintared for 15 min- utes toial in hydragen without using pre hat. Dimensional change is calculated from the die length dimension, The test method for dimensional change is ASTM B, 610 or MPIF 44. Tho seme exact vaues may not be oblaingd with commercial Sin- tenng practices due to diferences in part size, rate of heating, density ete. However, the relationships and the trends. shown between and among grades have been proven Sintesing bronze test bars Ima beltumeceTechnical Service ‘SCM Metal products isthe leader in pow- ers for sintered bronze bearings. We Understand the process and know nat only what is happening but why it occurs. Our people cen explain the PMB system and holp with grada salaction. Our enginaoring and technical staff will assist you in using PMB ponder by teaching proper produc tion practices and control. Finally we have the experience, backed by compiete labo- ratory faciities, to help solve ary problem tmat may come up in your operatons. SCM Metal Products has been helping users of cour bronze powders to be successiul for over 60 yeats. {In the manufacture of bushings the common determi- raion of sintered strength is based on the crush test from which a strength factor K, is calculated. For row- ‘tine QC tasts on powders, test bars are broken in transverse rupture to assure that the strength will be {great enough to meet minimum K factors. Results of transvoreo rupture strength tosts at diferent sintered densities between 5.7 and 6.3 gicm’ are shown in the graph. A band covers the range of typical strengths determined for all sic PMB grades. All theso irans- ‘verse rupture strengths will meet minimum K factors. The test specimens were transverse rupture bars pressed to a green density of 6.3 glem and sintered for 15 minutes in hydrogen at 1530°F (832°C) without Using preheat. The test for transverse rupture strength is ASTM B 628 or MPIF 41.Processing Variables The manufacture of sintered bronze involves the cortrol of many variables in order to meke quality bearings. By starting with a pre mixed power, the mixing and compositional variables are eliminated so that the fabricator can werk with a consistent raw material However, the conversion ofthe powder toa finished part stil involves cose contra, The folowing tables and graphs show the eect ‘of some processing variables on SCM Metal Products PMB semtes powders and are intended to guide the fabricator. Green density is the first variablo which fabricators using a pre- ‘mx need to control, Selection of green density establishes final bearing strength and cil content. The graph shows the etfect of ‘green density on dimensional change for three PMB grades. Data is based on TRS bars sintered In a mesh belt furnace at 1530°F (832°C) using dissociated ammonia atmosphere. ‘Typical data on other grades can be interpolated. Time toSiteina > 5 Tempe, 2 6 8 ‘imensona Cran Da 8.0 Tarowsenoue Stang TerowasoRupiye Sresga. hint sum 3100 58000, mo) The key to dimensional control of sintered branzeis the preheat or the rate of heating. Itis the most overtooked variable and will ‘cause more variation in dimensional change than anything else. Fumace design, atmosphere flow, pan size, Delt speed, and beltloading all fect the heating rate of the part Fast heat- ing rates tend to maximize dmensions, while siow heating ‘tas tend to minimize dimensions. The raph above depicts these effects for the various PMB grades. The table above shows the effect of various heating rates. “These data wero taken from 6.3 glem® density bars heated to 41590°F (832°C) at a number of controlled heat-up rates. Of ote here is the magnitude of the differance in dimensional ‘change which can occur by failure to understand and control the factors which amtect ine heat-up rate. Sintering time is the variable that establishes accuracy of ‘dimensional contro. As sintering proceeds, part dimensions wil fis\ go through a period of rabid expansion until maximum expansion is reached. Then, a gradual and predictable Secrease in dimensions will cur while homogenization takes place. Sinieting conditions should not be established forthe ris- Ing frst portion of the time curve. Dimensions are easiest 10 contro if parts are sintered either at ot past the maximum on the dmensional change versus time curve. Typical cata are ‘shown for a number of PMB grades in the graph. Data is from transverse rupture bars pressed to 6.3 g/cm and sintered in a laboratory furnace at 1530°F (682°C) in dissociated ammonia forthe times shown,Quality Control of Bearings ‘The six Key critera to a quality bearing are chemical composition, microstructure, dimensions, censiy, available porosity and sin tied strengt, Chemical composition is controlled by the starting powder. In the case of PMB powder, each lot is accompanied by a certificate of analysis lo assure that all industry specifications are met. Microstructure is developed during the sintoring proses when the tin melts and alloys with the copper to form bronze. It takes time and temperature to accomplish this. PMB's should be sintered at 1590°F (682°C) or just past the peak of the dimensional change va. temperature curve for 10 to 20 minules depending en beating sizo. The property sintered microstructure should be essenticlly all apha bronze as shown. There should be absclutely no evidence of free tin Figure 1 Figure 2 Properly Sintered Bronze Inadequately Sintered Bronze sraonicogtagn shows the es src fiatcon be “Thsphotomicogagh shows ne proses of ne gran ste ‘developed in 0/100 bronco, Nate te unerm gran stir ard areas ol fee cppos as orosuto! gone unasemverrg ‘tuning bande ane the eptarodaee pore Notte compote sbeonee ot tury tonae Obtimpregrated tosings ar ite the SCM laboratories. Degree of sintering can be approximated on the shop floor by examining the sur- face of a sintered pert which should show a dull bronze color with visible pores. A freshly fractured surlace should show uniform dull bronze throughout with no evidence of copper colored areas, Bearings are sized for dimensional control. A typical 1 (25mm) sleeve bearing would have an I.D. and 0.0. tol. erance of 0.0005" (0.013mm). Close control of dimen- ions during sintaring ie essential to achieve those eizod values The density of bearings is determined in a fully ciLimpreg: hated condition and must be 6.¢ to 6.8 gic Tor the pop- ular CT-1000-K26 bronze material, This bearing must also Contain a minimum oil content of 19% as determined by standard MPIF/ASTM est methods, The strangth of a cintored bronze bearing materialis moa. sured by a stength factor, K, test in which a bearing is crushed between paral! plates in a direction pependic ular to its axis. Under established formula, the material of CT-1000K26 must have a minimum 26,000 pei (180 Nimm#) strength constant, K.Powder Production and Quality Control Premixed bronze powders are, mixtures of 90% copper, 10% tin with 9426 vbr cant. The capper powder is procuced by ‘an atomization/oxidationvreduction pra- ‘e288 which results in a sponge-like part- le ideally suited to the manufacture of bearings. Tin powder Is produced by ‘atomization. ‘Quality starts with raw matorial. Copper is tested for trace elements and impurities. Our venders are rated and approved. Tin is purchased as primary ingot. In-process tesls an Statistical Process Control (SPO) at selected points in the manufac- turing process assure quality. Powders ‘are tested for chemical and physical properties. Bronze premixes are made from these elemental powders and aro quality tostod for all specified powder properties. Dimensional change is controlled at 4530°F (832°C) but musi also meat spec- ification limits at 1500 to 1560°F (B16 10 849°C). Strength tests are made to assure that K factor mnimums can be developed with the mix. Each shipment is ‘accompanied by a quality control analy- sis chest certiying chemistry, powder properties and sintered performance of the lot. Achioving consistency in lat to lot perfor. mance fas always been our primary uality goal. By adapting SPC we heve been able to achieve continued quality Improvement for our PMB grades. In the ‘graph below, we have plotied the total 6- ‘sigma range for dimensional change of PMB-8 at 1520°F (832°C) forall lots pro- ‘duced over an 8-year period. As can be seen, the dimensional change range has improved fom 1.2% to less than 0.6% ur goal is furthor improvement to less than 0.4%. This improvement will mean further pertormance consistency and ‘more reliability for the bearing producer.Trouble Diagnosis for Bronze Premixes Rogardioss of extensive Quality Control by the powdor suppor and caroful incoming Quality Checking by the powder user, there are sill times when what worked yesterday dovsn't work today. Whats diferent? Is the part the same, from the same press, through the same furnace? Is the powder lot the same ar diflerert? The following chart outlines possible correctons the part producer can make. The X's signify the remedies for each problem. PROBLEM | (A) | (8) | () | (O) | Ce) | (| | —> REMEDY cm | om | caeey | poor | tow | suartce lovstonron} HouR- | PART HAS comanae | cxawce | srrensma | wmcan- | siento | Aer Lassie | ODI ‘ow | “xpH | tow | wiry | srrenots |“ ance COLOR ILOHANGE GREENDENSTY | x x x x x 2 oeFIL 4. CHANGE SINTER TEMP. 4. HENGE HEAT-UP RATE 5, OHENGE SINTER TIME 6 FESNTER 1. AINOSPHERE 8. WORE Si2NG SQUEEZE 9 CHANGE FB GRADE ‘A. DIMENSIONAL CHANGE LOW (100 ‘much shrinkage or too ttle growth) — taster heat-up rate or an increase in aren density will increase dimen- sional change. Low dimensional ‘change ean ha corrected by incroasing sintering temperature when the part shows an under-sinlored_oonsition Increased hydrogen content in the fur- nace or a higher growin grad, if aval: able, will also inctease dimensions B, DIMENSIONAL CHANGE HIGH (100 much growth of not enough shrinkage) = A decrease in green densily of 2 shower rate of heating will decrease ‘dimensional change. Increased sinter time, decreased hydrogen content, or resintering wil also decrease dimen: sions. A lower growth grade will also decrease dimensions, i available. It pparis show a properly sintered cond tion, do nol lower temperature to reduce growth, . GREEN STRENGTH LOW - increased ‘green density resulting from increasing ‘compacting pressure or increased die fill_will increase the strength ol the ‘green part. D, POOR MACHINABILITY - Improved ‘machinabilty will reau from increased sintering temperature or time because alloying Is more complete and grain ‘growth is obtained E, LOW STRENGTH - Sintered strenath is improved by increasing green dersi- ty, increasing the sizing squeeze, increased sintering temperature beyond the peak growth temperature, increased sinter time, and resintering, F. SURFACE APPEARANCE ~ Above 68 ge’, parts wil frequently be pit- ted and have dirty surfaces unless agjustments are made to decre heat-up rate or decrease green density, if possible. G. DISTORTION ~ Distortion usualy results from aversintering. The sinter- ing temperature should be decreased. If die fil is uneven. density distribution will be uneven and distorted sintered parte can alee racult H. HOURGLASSING — Hourglessing controlled by minimizing density disti- bbutlon along the length of the part Poor die fill can accentuate the hour- glassing of long parts by increasing density differences between the ends and the center. |. REDDISH” COLOR — A bearing that has a reddish color hae not had an oppartunty for alloying ta be com- pleted. An increase in sintering tom- Peralure or time will correct, 10FOR POWDER METALLURGY: Copper, Tin, Electrolytic Iron, Lead, Nickel and Manganese Metal Powders, Stainless Stee), High Speed Sieels, cther Prealloyed Powders, Premixed Bronze and infiltrating Powders for P/M Compacting Copper and other Metal Powders for Friction Materials. ron Powders for Ferromagnetic Cores land Magnetic Parts. FOR METAL WORKING: Powders for Spray/Fuse and Puddee Torch Metal Surfacing. Cusiom Welding and Hatgacng Metal Powders. GUBOND® Copper Pastes for ‘mosphere Furnace Brazing. Nickel Base Brazing Filer ‘Metal Powders. GLIDCOP” jor Resistance Welding Electodes and Seam Welding Wheels. FOR SPECIALTY USES: Electrolytc Iran Melting Stock for Stee! Making. Metal Powders for Diamond Bonding anc Abrasive Matrixes. GLIDCOP® Dispersion Strengthened Copper for Electionic and Electrical Applications. Photocopior Powders. Coppor, Tin, Load, Iran and Stainless Stee! Powders for Additions to Plastics, Rubbers, Cements and Greases, MICROBOND* Solder Cream lor Electronic Uses. FOR CHEMICAL & CATALYTIC USES: Food Enrichment and Pharmaceutical Grado Iron Powder. Motals and Compounds for Catalysts and Chemical Reagents. Specialty Silane Catalysts. Cuprous Oxide for Anti-Fouling Paints. High Purity Iron Chips for Analytical Standards. United States Off SOM Metal Products, Inc. 2601 Weck Drive Box 12165 Research Triangle Park North Carolina, USA 27709-2166 Telophone: 919-544-8090 Fax: 919-544-7096 European Offic NN. SOM Europe S.A. “1, rue Saint Lambert B 1200 Brussels, Belgium TTalaphone: 32.2°7719110, Fax: 32-2.7714902 ‘Telex: 29007 (SCMEUR B) SCM METAL PRODLCTS, INC. Producing Quality Metal Products for Over 60 Years.