Enhanced flow in agglomerated and bound materials and process therefor

In broad terms, this process adds organic material to particulate solids and works the mix. Resolification in a unique way creates improved binding of the particulate solids. The particulate solids are materials such as metal, semi-metal, ceramic, glass, plastic, or rubber, alloy, composite, agglomerate, or other organic. The organic selection should remain solid in handling and may become liquid during compaction. These materials may consist of a liquid, solid or mixture selected from the group consisting of fatty acids; and amides, bisamides, soaps and salts of fatty acids, waxes, resin, oils, hydrogenated fats and oils, polymers, mold release or friction reducing agent. With lubricity enough to enable ejection of a molded compact, flow and adequately low molecular weight and formulation to enable clean burn off if desired. With inputs that may include either pressure, solvents, chemical activation of polymers, or thermal heat; and working so as to enhance the gluing of particulates together and rounding of the agglomerate to provide flowability.

EXAMPLE I In attempting to mold a cam shaft cover, weight 24.0 grams with Alcoa 201 AB and holding a 0.40 gram weight tolerance, the following was observed. Alcoa 201 AC is a blend comprised of &num;1202 Aluminum which is air atomized in Texas; &num;3014 a 50/50 copper/Aluminum master alloy is also atomized in Texas; elemental magnesium, and Acrawax C atomized as a lubricant. 1 The blend contains Min Max &num;1202 aluminum 93.60% 98.70% &num;3014 50/50 aluminum/copper 0.25% 4.4% Magnesium 0.5% 1.0% With organic lubricant 1.5% Trade name Acrawax aka N,N′-Ethylenebisstearamide 65%&bsol; N,N′-Ethylenepalmitamide 35% > Fatty Acid (C14-18) 2%/ Mesh size ˜5 Material &plus;50 &plus;100 &plus;200 &plus;325 −325 microns 1202 0.2% 18-22% 26-29% 16-20% 27-40% Aluminum max 3014 50/50 0.2% 75-90% copper/alum. max Magnesium 100% Acrawax 100% 50% Alcoa 201 AB as received Alcoa 201 AB Processed Press Grams of variation For agglomeration and flow Speed in set of 30 Grams of variation in group of 30 7-8 .58 10 6.07 .22 14 .31 20 .44 The mix was heated in the chamber in inert atmosphere to a temperature above the melting point of the Acrawax in this case 180° C. for 5 minutes (Acrawax melts at 145° C.). Acrawax has a boiling point of about 415° C. Working the material during cooling produced rounded agglomerates. The working and cooling was carried out for a period of time less than 1 minute. Acrawax is a registered trademark of Glyco Inc. 
 EXAMPLE II Another example of a sample holding—100 mesh of Ampal was made according to the procedure of Example I. This was a standard operating size so no changes were required to production. 2 The blend contains Min Max Aluminum 93.60% 98.70% Copper 3.6% 4.0% Magnesium 0.8% 1.2% Silicon 0.65% 0.9% With organic lubricant 1.5% Trade name Acrawax aka N,N′-Ethylenebisstearamide 65%&bsol; N,N′-Ethylenepalmitamide 35% > Fatty Acid (C14-18) 2%/ Mesh size ˜5 Material &plus;50 &plus;100 &plus;200 &plus;325 −325 microns Aluminum 1.0% 25-45 30-50 20-40 max Copper 100% 18-24 Magnesium 100% 18-24 Silicon 100% 18-24 Acrawax 100% 5-6 Ampal 2712 processed For agglomeration and flow Press Speed Grams of variation in group of 30 10 .18 14 .16 20 .22 
 EXAMPLE III A metallurgic bronze powder system comprised of 90% elemental copper and 10% elemental tin was pre-alloyed, atomized and reduced to a powder. The bronze powder and Acrawax-C atomized the lubricant to be made a binder, were loaded into a crucible or melting chamber. The mix was heated in the chamber in inert atmosphere to a temperature above the melting point of the Acrawax in this case 180 C. for a 5 minutes (Acrawax melts at 145 C.). Working the material during cooling produced rounded agglomerates. The results show a greater consistency of die filling due to binding and flow-ability of the mix. Larger particles usually accompany higher permeability allowing for greater flow rates. Agglomerate shape dictates the mixes free motion. The agglomerate ability to roll past other agglomerated particles. The results also show binding retards sifting segregation and facilitates greater homogeneity of alloy distribution regardless of particle size. This narrows the range of strength of a compact as measured across a narrow cross-section hence increasing strength as measured from the lesser number. Less distortion of deformation of the component also is seen after sintering. Multiple pre-bound materials mixed together to allow for creation of alloy pins, inclusions, nodes and structure within a greater component is also possible, in addition to multiple matrix components. The process has less dusting which helps with equipment uptime due to cleanliness, consistency of die filling, housekeeping, health, benefits due to reduction of nuisance dust and the reduction of potential explosions due to air borne oxidizing or reactive materials. The agglomerates may also be ionized facilitating transfer to or from a charged target. Lubricant as a binder, reduction of particle/particle or agglomerate/agglomerate friction during compaction and reduction of die wall friction during ejection occurs, over a process using less lubricant and more binder. Indications are that typically compressibility is decreased slightly, the lubricant is now fixed by the process and not free flowing. If the temperature of the tools are below the melting point of the bound lubricant and it achieves liquid state during compaction; compressibility is restored as the lubricant is dislocated and the bound lube is squeezed out to the die wall where it may better aid in ejection after compaction. These relatively chilled tools must freeze the binder and with subsequent relative cooling protect the part from free mix sticking to the part. In addition to these embodiments, persons skilled in the art can see that numerous modifications and changes may be made to the above invention without departing from the intended spirit and scope thereof.