Ceramic Shells for P/M Near-Net-Shape Forming

An improvement to a power metallurgy near-net-shape consolidation process, Radially Constricted Consolidation (RCC) process, is proposed. Program objective is to develop complex shaped ceramic containers (shells) for soft die hot pressing of powders using the RCC process. Shells to be developed are intended for consolidation of copper alloys, iron, iron base alloys, and stainless steels. Taguchi methods will be used to design and execute the experimental study. Experiments will involve design factors such as shell chemistry, time and temperature of drying, particle size, etc. If successful, the results will allow commercialization of the RCC process for small and medium sized P/M parts. Phase II work will scale-up the shell size, provide scientific understanding of successful shell compositions, and produce prototype parts, and test them. The RCC process has the potential of becoming a major P/M process which can expand markets served by the P/M industry into larger and more complex shaped parts. Anticipated Benefits: The proposed research and development effort will allow the potential of the RCC process to be realized. Manufacture of small and medium sized complex shaped parts, up to now impossible to manufacutre by any other P/M process, will be possible. Many castings and welded assemblies, including those used in aero-space applications, may be replaced by RCC products with better properties and lower cost.