Yes, in most cases. Traditionally we are trying to balance the density of a part so that they are similar throughout the part, however, sections of a part have the potential of being designed with lower or higher density.

Answer: Yes. 

Best Practices for Welding Sintered Metals

• Keep parts free of contaminants 
  
  • Residual lubricants, coolants or cleaning solution reduces the weld integrity.
• Select material with a lower carbon content
  • The materials with a 0.0 - 0.5% perform better than the higher carbon blends
• Use a higher density 
  • Parts with densities above 6.8 g/cc provide improved weld contact areas 

Answer: Yes.

Since powdered metal components are porous, the absorption of contaminants into PM parts poses a difficulty as well as a flame hazard for welding. Preventing contaminants from being absorbed into the part is critical in weld applications.

Simple Test to Identify the Presence of Porosity Contaminants in PM Parts

• Atlas uses a hot plate test that is also commonly used by our platers, which will show if there are contaminants in the part. This test consists of heating the hot plate to between 150°-350°F and placing the part on the hot plate. The temperature range will depend on the type of contaminant that you might expect to see in the part. A “smoking” part is a tell-tale sign.

Steam treatment is a thermal process that creates a thin controlled oxide layer on the surface of an iron-based metal component.  Steam treatment can provide a component with increased corrosion resistance, hardness, density, and magnetic properties.  It can also be used to seal the porosity and improve its wear characteristic. 

Steam treatment is a batch process with minimal inputs and has been proven to be a cost-effective solution for many applications.  Components transferred to steam treat must be kept clean and dry as it is necessary to avoid contaminants or residue on or in the structure prior to processing because it will impact of how well the oxide layer forms on the surface.

As in most thermal treatments, time, temperature and atmosphere are controlled to provide the optimal conditions for the expected finish.  The desired properties of the component will dictate what time and process parameters are used for a given part. During a typical steam treatment process, parts are placed in a steam treat unit and heated to approximately 1000° F.  Once the component is at temperature, steam is introduced and the water vapor reacts with the iron to form the oxide layer (magnetite - Fe3O4).  After a designated period of time, the component is removed from the unit and allowed to cool. The oxide appears on the component surface as a blue/black finish.

Components are copper infiltrated for a number of reasons. Some basic desired results are improvements to tensile strength, hardness, impact properties, and ductility. Copper-infiltrated components will also have a higher density.