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Powder Metallurgy

Overview

Powder Metallurgy High-Speed Steel (PM HSS) represents a significant advancement in tool steel technology. By utilizing powder metallurgy (PM) processes, PM HSS offers superior properties compared to conventionally produced high-speed steels. PM HSS is highly regarded for its exceptional hardness, wear resistance, and toughness, making it an ideal material for high-performance cutting tools, cold work tools, and complex shapes that demand high precision and durability.

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Characteristics

PM HSS exhibits several superior characteristics due to its unique manufacturing process, which sets it apart from cast and forged high-speed steels:

No Segregation: PM HSS does not suffer from alloy segregation, ensuring uniform properties throughout the material.
Fine Grain Size: The powder metallurgy process results in fine grain size, contributing to better mechanical properties.
Fine Carbide Particles: The carbides are uniformly distributed and fine, improving wear resistance and toughness.
Excellent Hot Workability: PM HSS has superior hot workability compared to traditional high-speed steels, making it easier to shape and form.
Superior Grindability: PM HSS can be ground to a fine finish with ease, which is crucial for precision tools.
Minimal Heat Treatment Deformation: The material undergoes less distortion during heat treatment, maintaining its dimensional accuracy.
Enhanced Mechanical Properties: PM HSS exhibits excellent toughness, hardness, and high-temperature hardness, essential for demanding applications.
Expanded Alloy Content: The PM process allows for higher alloy content, leading to the development of ultra-hard high-speed steels.
Broadened Application Range: The superior properties of PM HSS have expanded its use in various industries, including automotive, aerospace, and tool manufacturing.

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Production Process

The production of PM HSS involves atomizing a molten alloy into fine powder particles, which are then compacted and sintered to form a solid billet. This process ensures a uniform distribution of carbide particles and eliminates the segregation issues commonly found in conventionally produced high-speed steels. The PM process provides the following benefits:

Fine and Uniform Microstructure: The homogeneous distribution of carbides leads to improved mechanical properties and wear resistance.
Minimal Alloy Segregation: The elimination of carbide segregation enhances the steel’s toughness and machinability.
Improved Dimensional Stability: Reduced thermal expansion and distortion during heat treatment.

Applications

PM HSS is widely used in various industries due to its outstanding properties:

Cutting Tools: Ideal for manufacturing complex, high-performance cutting tools such as end mills, drills, taps, and reamers. The superior wear resistance and red hardness of PM HSS ensure long tool life and consistent performance.
Cold Work Tools: Used in the production of punches, dies, and other cold work tools that require high toughness and wear resistance.
Plastic Molds: Suitable for plastic mold components where dimensional stability and wear resistance are critical.
Precision Components: Ideal for manufacturing precision components in the aerospace, automotive, and medical industries.
Automotive Industry:A leading automotive manufacturer reported a 50% increase in tool life and a 30% reduction in downtime by switching from conventional HSS to PM HSS for their cutting tools.
Aerospace Industry:An aerospace component supplier achieved improved precision and longer service life for their high-performance drills and reamers, resulting in significant cost savings and enhanced product quality.

Common Sizes

1. Round Bars

Diameter Range: 10mm to 500mm
Length Range: 3000mm to 6000mm

2. Flat Bars

Thickness Range: 5mm to 200mm
Width Range: 20mm to 1000mm
Length Range: 2000mm to 6000mm

3. Square Bars

Side Range: 10mm to 300mm
Length Range: 3000mm to 6000mm

4. Plates

Thickness Range: 10mm to 400mm
Width Range: 1000mm to 2000mm
Length Range: 2000mm to 6000mm

5. Sheets

Thickness Range: 1mm to 6mm
Width Range: 500mm to 1500mm
Length Range: 1000mm to 3000mm

Chemical Composition

Powder Metallurgy High-Speed Steel
NO.	ASTM Grade	Chemical Composition (Mass Fraction) /%
NO.	ASTM Grade	C	Cr	V	W	Mo	Co
1	PM M4	1.42%	4.00%	4.00%	5.50%	5.25%
2	PM T15	1.60%	4.00%	5.00%	12.00%		5.00%
3	PM M2	0.85%	4.15%	2.00%	6.40%	5.00%
4	PM 10V	2.45%	5.25%	9.75%		1.30%
5	PM S390	1.64%	4.80%	5.00%	10.00%	2.00%	8.00%
6	PM S290	1.30%	4.50%	5.00%	10.00%	1.30%	8.00%
7	PM 3V	0.80%	7.50%	2.75%		1.30%
8	PM M42	1.10%	3.75%	1.15%	1.50%	9.50%	8.00%
9	PM 4V	1.35%	7.75%	3.75%		2.75%

Comparison Table of Steel Grades by Country

Powder Metallurgy High-Speed Steel
NO.	ASTM	ISO	DIN	JIS
1	PM M4	HS 6-5-4	1.3346	SKH54
2	PM T15	HS 10-4-3-10	1.3207	SKH58
3	PM M2	HS 6-5-2	1.3343	SKH51
4	PM 10V
5	PM S390
6	PM S290
7	PM 3V
8	PM M42	HS 2-9-1-8	1.3247	SKH59
9	PM 4V