Patent ID: 8062582
Filing Date: 2011-11-22
Classification: B22F

Abstract:
1. A method of forming a metal part comprising the steps of: (i) providing a metal powder composition comprising a blend of (ii) compacting the metal powder composition within a die cavity to form a green compact, wherein the organics package is spread onto the outer surface of the primary metal particles in the green compact; (iii) delubing the green compact in an inert atmosphere; and (iv) sintering the delubed green compact to a peak sintering temperature at a heat up rate of 60° F./min or higher to form the metal part, wherein the metal oxides on the surface of the primary metal particles in the green compact are removed in situ in a reaction with the organic acid, lubricant and/or the carbon residue from the organic compound other than the lubricant or organic acid at a temperature below which liquid phase bonding and/or solid state diffusion occurs in the sintering step, and wherein the metal part has a sintered density that is ≧26% of a theoretical density for all metallic constituents of the metal powder composition immediately after the sintering step and prior to any further post-sintering densification steps.