• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09b
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• pp.738-739
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• 2006

This paper will describe a powder and processing method that facilitates single press-single sintered densities approaching $7.5g/cm^3$. At this sintered density, mechanical properties of the powder metal (P/M) component are significantly improved over current P/M technologies and begin to approach the performance of wrought steels. High performance gears have the added requirement of rolling contact fatigue durability that is dependent upon localized density and thermal processing. Combining high density processing of engineered P/M materials with selective surface densification enables powder metal components to achieve rolling contact fatigue durability and mechanical property performance that satisfy the performance requirements of many high strength automotive transmission gears. Data will be presented that document P/M part performance in comparison to conventional wrought steel grades.

• Proceedings of the Materials Research Society of Korea Conference
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• 1998.11a
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• pp.85-85
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• 1998

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.389-390
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• 2006

Selective surface densification is a tool for improving the mechanical properties of PM steels, such that the requirements for highly loaded gears can be matched. This paper describes the manufacturing and the properties of a helical P/M gear. The gear performance was evaluated on a 3-shaft back to back test rig, on a load bearing test rig and on a sound test bench. The results of these tests are presented and compared to data obtained from solid steel gear with identical geometry and surface quality. This comparison indicates that P/M gears have a load bearing capacity and noise level which are both well comparable to solid steel gears.

• Journal of Powder Materials
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• v.24 no.3
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• pp.187-194
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• 2017

Selective laser melting (SLM) can produce a layer of a metal powder and then fabricate a three-dimensional structure by a layer-by-layer method. Each layer consists of several lines of molten metal. Laser parameters and thermal properties of the materials affect the geometric characteristics of the melt pool such as its height, depth, and width. The geometrical characteristics of the melt pool are determined herein by optical microscopy and three-dimensional bulk structures are fabricated to investigate the relationship between them. Powders of the commercially available Fe-based tool steel AISI H13 and Ni-based superalloy Inconel 738LC are used to investigate the effect of material properties. Only the scan speed is controlled to change the laser parameters. The laser power and hatch space are maintained throughout the study. Laser of a higher energy density is seen to melt a wider and deeper range of powder and substrate; however, it does not correspond with the most highly densified three-dimensional structure. H13 shows the highest density at a laser scan speed of 200 mm/s whereas Inconel 738LC shows the highest density at 600 mm/s.

• Journal of Powder Materials
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• v.5 no.3
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• pp.199-209
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• 1998

A new low melting inorganic binder, monoclinic $HBO_2$, has been developed for Selective Laser Sintering (SLS) of alumina powder by dehydration process of boron oxide powder in a vacuum oven at $120^{\circ}C$. It led to better green SLS parts and higher bend strength far green and fired parts compared to other inorganic binders such as aluminum and ammmonium phosphate. This appeared to be due to its low viscosity and better wettability of the alumina particle surface. A low density single phase ceramic, aluminum borate ($Al_{18}B_4O_{33}$), and multiphase ceramic composites, $A_{12}O_3-A_{14}B_2O_9$, were successfully developed by laser processing of alumina-monoclinic $HBO_2$ powder blends followed by post-thermal processing; both $Al_{18}B_4O_{33}$ and $A_{14}B_2O_9$ have whisker-like grains. The physical and mechanical properties of these SLS-processed ceramic parts were correlated to the materials and processing parameters. Further densification of the $A_{12}O_3-A_{14}B_2O_9$ ceramic composites was carried out by infiltration of colloidal silica, and chromic acid into these porous SLS parts followed by heat-treatment at high temperature ($1600^{\circ}C$). The densities obtained after infiltration and subsequent firing were between 75 and 80% of the theoretical densities. The bend strengths are between 15 and 33 MPa.

• Journal of Korea Foundry Society
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• v.23 no.5
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• pp.244-250
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• 2003

The aim of this study is fabricating of composite filler metal (CFM) by a combination of selective laser sintering (SLS) of stainless steel powders (RapidSteel $2.0^{TM}$ and liquid phase infiltration of Ag-28 wt.%Cu alloy. Porous stainless steel body with inter-connected pore channels was fabricated by SLS, binder decomposing and densification processes. By the direct contact infiltration, the narrow inter-particle channels of the porous body were completely filled with the Ag-28 wt.%Cu alloy infiltrant. During infiltration, the dissolved elements of Fe, Ni and Cr from the porous body were solved into copper solid solution phases, which consist of eutectic structure of composite metal matrix. The S10C/CFM/S10C joints, which have narrow clearance gaps between them up to 10 micrometers, were joined successfully by self-feeding of filler metal from the matrix of CFM. The CFM kept its original thickness and microstructure after brazing. The tensile strength of brazed specimen was higher than 30 kgf/$mm^2$ and showed a typical ductile fracture mode in the CFM.

• Journal of Powder Materials
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• v.26 no.2
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• pp.138-145
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• 2019

In this study, Al-Si-Mg alloys are additively manufactured using a selective laser melting (SLM) process from AlSi10Mg powders prepared from a gas-atomization process. The processing parameters such as laser scan speed and laser power are investigated for 3D printing of Al-Si-Mg alloys. The laser scan speeds vary from 100 to 2000 mm/s at the laser power of 180 and 270 W, respectively, to achieve optimized densification of the Al-Si-Mg alloy. It is observed that the relative density of the Al-Si-Mg alloy reaches a peak value of 99% at 1600 mm/s for 180 W and at 2000 mm/s for 270W. The surface morphologies of the both Al-Si-Mg alloy samples at these conditions show significantly reduced porosities compared to those of other samples. The increase in hardness of as-built Al-Si-Mg alloy with increasing scan speed and laser power is analyzed due to high relative density. Furthermore, it was found that cooling conditions after the heat-treatment for homogenization results in the change of dispersion status of Si phases in the Al-Si matrix but also affects tensile behaviors of Al-Si-Mg alloys. These results indicate that combination between SLM processing parameters and post-heat treatment should be considered a key factor to achieve optimized Al-Si alloy performance.