The PoP Centre Primed to help you imagine new possibilities
Höganäs AB (publ.), December 2012. 0299HOG Höganäs AB (publ.) SE-263 83 Höganäs Sweden Phone +46 42 33 80 00 Fax +46 42 33 83 60 www.hoganas.com
The PoP Centre Our common goal is to grow the world of metal powders. Höganäs wants to contribute to our industry reaching its full potential. We think this can only be done by working together. Future success is to be found in the close interaction between application knowledge, design aspects, process and powder materials. We hope that our PoP Centre will become a place where Höganäs and its partners can join forces, in close cooperation, to innovate and drive the business forward. Here we have the infrastructure to work with material development, application design and prototyping as well as process optimisation, an ideal platform for joint application engineering within the areas of PM components, electromagnetic applications, surface coating and many other powder application segments. You can use the Centre as a source of inspiring ideas and employ its services to develop, test and rapidly prototype new concepts. Through partnership we can push the limits of the powder technology, improve performance, win new applications and expand markets.
The vision of the PoP Centre is to make metal powder technology the first choice by helping customers and endusers to utilise the Power of Powder. Powder products are developed and manufactured for several different segments by Höganäs worldwide: Components Surface coating Joining sintered components, soft magnetic composites, friction, filters, metal injection moulding laser cladding, thermal spraying brazing, welding These product segments will now be supported by the PoP Centre to provide a more integrated development approach for products and solutions. The services range from straightforward prototyping or mechanical testing to complete application development as exemplified by SMC (Soft Magnetic Composites) where support encompasses material selection, application design and process solutions. The Centre provides a good platform for working in teams in the whole value chain a key to profitable growth. 4
The materials expertise to select the right powder solution. The process know-how to ensure optimum production efficiency and quality. The design support to create innovative applications. The PoP Centre s service categories: Testing... 4 Material Analysis... 6 Component Testing... 8 Process Development... 10 Compaction... 12 Sintering... 14 Machinability... 16 Application Development... 18 Brazing Applications... 20 Electromagnetic Applications... 22 Laser Cladding... 24 Prototyping... 26 Off-tool Sampling... 28 Novel Sintering and Heat Treatment Process... 30 Training... 32 5
Testing Making it easier to select the right powder-based product Material characterisation and testing has traditionally been one of the strongest competencies that Höganäs offers. By adding new component test methods such as wear testing to established competence in areas like fatigue analysis, the PoP Centre can provide a wide range of material and component testing methods. Mechanical testing static properties, dynamic properties, wear Material analysis metallographic analysis, powder properties, rheology, phase transfer analysis Chemical testing corrosion testing, wet chemical analysis, material composition, compound analysis Component testing gear strength testing, wear testing Advanced testing methods enable virtual prototyping and the generation of reliable application-relevant data to product and process designers. 6
Comprehensive facilities for testing mechanical properties. 7
Material Analysis PM has a unique advantage over conventional manufacturing processes the ability to design microstructures. Our facilities for metallography-based material analysis can help you realise the full design potential of powder metal. Analysis for predicting material performance. 8
Making the right material selection Using Höganäs materials knowledge and microstructure analysis tools makes it possible to design materials with specific properties and to select the right material and processing for a given application. Microstructure analysis also has a troubleshooting role, providing the insight to identify root causes for application failures and the ability to indicate corrections to processes and materials that will ensure robust manufacturing. Full spectrum of microstructure analysis tools The PoP Centre gives you access to our complete spectrum of analysis tools and investigation methods, allowing you to utilise microstructure analysis both for developing the innovative PM part designs of tomorrow and solving today s immediate component quality problems. We also arrange courses on metallography to spread knowledge and understanding on the potential and behaviour of PM materials. Microstructure and the big picture Utilising our resources to find out more about component microstructure can bring you a range of benefits, both in the short and long-term. These range from the rapid solution of emergency component quality problems and fast identification of failure root causes to providing the in-depth analysis to ensure a high quality standard for powder solutions, which helps to improve the big picture for the PM industry. 9
Component Testing For a range of components, such as gears and cam lobes, fatigue and wear testing is vital in order to give designers reliable design information. The PoP Centre offers a new source for applicationrelevant wear and fatigue data. Obtain reliable fatigue and wear data At present CAD and CAM technologies cannot cover important aspects of engineering design such as contact fatigue and wear. It can be difficult for component designers to find wear and fatigue test data relevant to their target application. The PoP Centre provides a new way to fill this information gap by offering fatigue and wear testing as well as access to a range of other testing methods. New wear testing capability The PoP Centre provides an efficient fatigue analysis service based on many years experience of fatigue testing and proven gear tooth bending test methods. Gear pitting resistance testing is carried out on a test rig that has been specially developed in-house. New testing facilities at the PoP Centre mean Höganäs is offering adhesive friction/wear testing and abrasive wear testing for the first time. 10
Use our expertise and experience in component testing. Easier selection of materials Component fatigue and wear testing can give you relevant and reliable component design data and provide an efficient route to the performance ranking of materials/processes, making it easier to choose a suitable powder solution. The testing service can be used with the PoP Centre s other capabilities as a part of your development process to achieve new PM applications in fatigue and wear environments. 11
Process Development In the past, Höganäs has developed processes such as warm compaction for its customers and we continue to be involved in joint projects to offer new alternatives and improve processing performance. Increasing competitiveness New developments in sintering provide opportunities for the controlled sintering of high-performance powders such as chromium materials. Cooperation with press and tool manufacturers on the use of our Starmix BOOST pressready mix has improved the productivity and quality of PM components. The PoP Centre will provide services that aim to optimise customer processes in areas such as pressing and sintering, and post treatment stages like machining. 12
Work with process development. 13
Compaction The PoP Centre can simulate real-life compaction conditions, enabling the testing of lubricants and new powder compositions, optimisation of pressing parameters and fast delivery of green or sintered blanks. Optimising compaction Compaction s crucial role in PM component production means optimisation of the compaction process is vital for achieving wider industry aims such as improved productivity, densities, precision and performance. To support you in the optimising of pressing parameters and to provide a service for the rapid production of blanks, the PoP Centre has installed a new fully hydraulic, multi-level Dorst 800-ton press. State-of-the-art pressing technology The Centre gives you access to state-of-the-art compaction capacity. Besides compacting multi-level components, we can also offer to compact blanks of different sizes and shapes such as disks, rings and rectangular samples in tailored-made materials that can then be used in the prototyping process. You can also gain access to other smaller presses a 45-ton mechanical press and 120 or 400-ton hydraulic presses. 14
Comprehensive compaction analysis Providing production-like compaction conditions offers you a unique opportunity for monitoring parameters such as different forces, part temperature, weight scatter and ejection energy in a production rate process. The Centre combines new and existing compaction capabilities to offer you an effective, cost-effective service for selecting the right powder formulation, most suitable mix composition and press parameters for your application. Look at compaction from all angles. Lorem ipsum dolor sit amet... In med kort bildtext. 15
Sintering The quality of any PM product is directly related to control of process parameters. The PoP Centre brings together a range of services to ensure you can achieve successful control of the sintering process. Greater control of the sintering process is within reach. 16
Optimising the sintering process We can help you to get the most out of your sintering process by identifying the most suitable process conditions for optimising the material performance for your application. Process tests on your material can be carried out in robust conditions on Höganäs sintering equipment. We also offer quality assurance testing (with controlled atmospheres) of highperformance alloyed powders such as chromium materials. Improving sintering control Our equipment and services include Sinterflex, a new technology jointly developed by Linde AG and Höganäs, for enhanced control and monitoring of the sintering atmosphere for alloyed powders. Prototypes produced via the PoP Centre can be sintered under your recommended controlled atmosphere. There is also an option to use our metallographic investigation resources to verify a sintering atmosphere s effects. All aspects of sintering support The full range of sintering services includes a troubleshooting team that can investigate disturbances in your sintering process, and training courses in sintering arranged as internal seminars at your site or at our PM School. Utilising our sintering support services will help you achieve smooth, cost-efficient sintering processes optimised for your specific applications. 17
Machinability Improving the machinability of PM steels can make PM components more competitive. Using the PoP Centre s machinability testing services can help you boost productivity and reduce machining costs. Machining of PM component. 18
The CNC turning lathe. Insight on cutting parameters The machinability of PM materials, such as sintered or sinter hardened PM steels, is not generally regarded as being comparable to conventional steels. Our challenge is to gain insights on machinability that enable us to optimise key cutting parameters additive enhancers, tool grades and geometries, speed and feed rates for specific PM materials and thus improve machinability. Enhance machining performance The Centre s capabilities can help you evaluate and identify the most suitable material, process and machining enhancers to achieve the best possible machining performance. At the heart of our machinability analysis resources is a CNC turning lathe and a 5-axis CNC vertical machining centre, which can perform turning, drilling or milling tests, providing data on a range of key machining parameters. More cost-efficient machining Detailed insight on a PM material s machinability can enable you to create the optimum overall conditions for machining. This knowledge is valuable for your production process in two respects; by making it easier and faster to solve any machining-related problems, and by enhancing the efficiency of machining routines, making it possible to reduce machining costs, increase productivity and prolong tool life. 19
Application Development If the PM industry is to grow, cooperation is needed to find new markets, convert opportunities and optimise existing solutions. You can utilise the PoP Centre s range of services to support innovative application development. Highlighting the opportunities One of the PoP Centre s important roles is to help you identify new conversion opportunities. Recent system teardowns have shown conversion potential in applications ranging from power tools and lawn mowers to all-terrain vehicles. Our test car with a converted gearbox is one example. After more than 100,000 km on the roads it has shown that PM transmission gears are ready to meet automotive industry needs. Another example is our 4 th transmission PM gear pair which was used in a 300 HP rally car under the toughest driving conditions. Heat exchangers, food fortification, electric motor parts, automotive components - the diversity of powder metal applications is endless... 20
Applying our services All the Centre s services can be drawn on for application development, but the most relevant are system teardowns, market scanning, concept development, component prototyping and PM-ification. The PM-ification process offers full-chain development for conversion candidates from idea through design support to fully functional prototypes, resulting in a more PM-suitable, ready-to-test component. Pursuing the possibilities The PoP Centre s capabilities to help you explore new application opportunities relate not only to PM components, but also to brazing, surface coating, SMC and all other powder product segments covered by Höganäs. Our partnership can assist you in identifying new openings and gaining the proof of concept needed to pursue applications that create new business and expand markets. 21
Brazing Applications With state-of-the-art equipment for screen printing, roller coating and dispensing, we can help you reach high precision, high productivity and low defect rates in all types of brazing applications requiring nickel-braze alloy properties. Customer support every step of the way We provide customer support every step of the way. We are deeply involved prior to product delivery, offering expert development advice to ensure an optimum solution. On-site application development is also provided to ensure we find the optimum application solution for your components. For all kinds of application techniques No matter what your brazing requirements are, we provide you with support leading to successful results. Our roller-coating equipment can help you achieve thin coatings on, for instance, flexible fins or structured plates. With our screen printer, you can selectively apply paste to where it is required. When you are looking for simple and clean paste application on heat exchangers we can help you find the optimum dispensing solution. 22
Proving production concepts The roller coater, screen printer and dispensing unit in the PoP Centre can all be integrated in mass production with parameters targeted to customers processes. We can provide test series of components with paste applied the same way as in final production in order to make sure the customer s productivity and quality requirements are fulfilled. Screen printing. 23
Electromagnetic Applications SMC technology opens up new opportunities to design compact, costefficient electromagnetic applications. With the PoP Centre, we can provide the know-how and services needed to reduce time to market for innovative SMC projects. A competitive alternative Soft Magnetic Composites (SMC) challenge traditional materials in applications with alternating magnetic fields. With unique magnetic properties in 3 dimensions and net shaping capabilities, Somaloy the SMC concept brand from Höganäs is a competitive alternative to electrical steels in applications such as rotating and linear machines, sensors, fast switching solenoids and inductive components. From concept to commercial reality SMC has great potential, but the main challenge is to take electromagnetic applications from concept to commercial reality. This requires a multidisciplinary approach focusing on material selection, application design and an efficient solution for producing the pressed, heat-treated components. We offer you the know-how, tools, equipment and services to support a successful project outcome. 24
Delivering innovative solutions based on specific market requirements. Full service for electromagnetic applications Our range of capabilities provides market support in areas such as material selection, training and prototyping. It enables effective partnerships in dedicated application projects providing support on application design using FEA analysis, production optimisation, and the building and testing of new electromagnetic applications. 25
Laser Cladding Surface coatings offer a potential growth area for the PM industry. Höganäs provides a full application development service for high-tech, powder metal-based surface coating methods such as laser cladding. Enhancing surface properties A number of surface coating techniques can be used to enhance surface properties such as wear and corrosion resistance. Laser cladding, used in industries such as oil drilling, mining and power generation, is a build-up welding technique that applies the coating via a molten phase. Materials used in laser cladding, generally nickel, cobalt or iron-based, provide surface coatings with good protection against corrosion and wear. Developing applications We can support you in all aspects of application development. This can cover identification of the best solution to improve component lifetime, selecting the optimum process and material, providing you with prototypes or applying the coating directly on your existing product. We can also back you up with technical support on process parameters and materials, and provide a troubleshooting service. 26
Improving resistance As well as laser cladding, Höganäs powders are suitable for high-tech surface coating methods such as Plasma Transferred Arc (PTA) surfacing, High-Velocity Oxy-Fuel (HVOF), plasma or flame spraying and powder welding. With our services you can identify, develop, prototype and test competitive cost-effective solutions that improve wear and corrosion resistance and open the way to new applications. Laser cladding is an advanced solution for superior wear and corrosion resistance. 27
Prototyping Would you like to speed up the component prototyping process and reduce the risk and cost involved? Our rapid prototyping service helps you evaluate and verify component concepts faster and cut time to market. A new alternative for prototype generation Customers and end-users often face a number of challenges in developing new PM applications. Prototypes made from pressing tools can involve high costs, considerable first step in confirming component performance, considerable risk and long lead times. The capabilities of the PoP Centre offer a new, fast and cost-effective alternative for generating advanced PM prototypes for new application developments. 28
Advanced CAD and FEA support optimises component design. A complete prototyping service We can offer support and services every step of the way from concept stage to ready-to-test prototypes. Our in-house CAD and FEA capabilities can assist in optimising key component design aspects. The optimised CAD solution can then be connected to our 5-axis CNC machining centre for rapid production of prototypes from sintered pucks for testing or design verification. A toolbox for your development needs You can use our material selection expertise, design support and machining & testing capabilities to identify the optimum process-design-material combination for your application a process that can help you reduce the number of design iterations. Our services offer you the opportunity to confirm real component performance and reduce the time, cost and risks usually associated with development. 29
Off-tool Sampling Want to test new design concepts or challenging compaction jobs without troubling your production? Employ external test capabilities and press technology to verify and optimise compaction feasibility. A new alternative for production trials Meeting OEM delivery times while striving for best possible equipment utilisation and quick tool changes are common customer challenges. The results are often a lack of both time and suitable in-house equipment for new application development or production trials. Besides PM material competencies, we can provide external development capabilities in the PoP Centre, including various pressing and sintering capacities at your service. All adjacent services We provide the most suitable powder formulations, including access to latest lubricant and additive developments, press capacity up to 800 tons (CNC, multilevel, helical gear adaptor) and much more. All commonly used sintering atmospheres and temperatures are available and necessary density and metallographic evaluation services are provided on site. 30
Tooling and adaptation support from the experts Bring your own tooling and compaction experts or benefit from our partnership with industry leading PM tool expert Alvier AG PM-Technology and press manufacturer Dorst Technologies. With our combined team of experts your own shop floor can be extended and your project a success. Our services can help you proove a new PM concept or to off-tool real prototypes while reducing time, cost and risks without troubling your own shop floor. Helical gear compaction tool. 31
Novel sintering and heat treatment process High-strength applications provide a great potential to grow the PM industry but may require special processes. The PoP Centre s new sintering and heat treatment furnace enables cost effective surface hardening of chromium alloyed PM components. Sintering and heat treatment furnace from ECM Technologies. 32
Pilot production of high-performance applications Höganäs unique chromium alloyed powders provide costefficient solutions for high-performance applications such as transmission gears. However, chromium alloyed PM components cannot be heat treated by conventional gas carburising and oil quenching. Low pressure carburising (LPC) and gas quenching facilitates surface hardening of components based on such powders and helps meet stringent requirements on quality and dimensional accuracy. The PoP Centre s stateof-the-art furnace from ECM Technologies enables hightemperature sintering and hardening of PM parts in pilot scale. The combined process saves both costs and energy by eliminating the cooling and re-heating stages required by conventional gas carburising and oil quenching. The technology offers further environmental advantages by decreasing C0 2 emissions from the process gases and by avoiding disposals of quenching oils and cleaning chemicals. With state-of-the-art pilot production capacity in both compaction and sintering, the PoP Centre is ready to develop your next generation of high-performance PM applications that can help grow the market for powder technology. 33
Training Höganäs has arranged many PM Schools over the years. Other courses cover areas such as Brazing, SMC, Surface Coating and Metallography. All courses are customised according to the customer s needs. 34
Contact the PoP Centre Please contact your local sales representative. Find your local office at www.hoganas.com. For general enquiries, you can also email to: infopop@hoganas.com. www.hoganas.com
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