HIP Powder Metal Near-Net Shapes for Demanding Environment and Applications

Abstract

Abstract Sandvik Powdermet AB in Surahammar, Sweden has been the leading supplier of near net shape powder metal (PM) hot isostatically pressed (HIP) components since 1985. All together several thousands of tonnes of fittings, valve components, manifolds, swivel parts, diesel engine nozzles, turbine parts, centrifugal separators and components for medical purposes have been successfully produced. This paper will review a number of applications of interest for demanding industries as the Oil and Gas and other energy related communities. The production and engineering facilities in Sweden and the US involve inert gas atomisation of powder, 3D CAD capsule design, sheet metal capsule fabrication and large HIP systems capable of producing individual parts as large as about 14 tonnes followed by heat treatment, pickling, machining and final inspection. The major applications are for the Oil and Gas Industry especially in offshore and sub sea applications. Other applications are for the Industrial Power Generation, the Pulp and Paper, the Pharmaceutical and Traditional Engineering Industries. Typically the components replace castings, forgings and fabricated parts and are produced in grades such as Martensitic steels, Austenitic and Duplex (Ferritic/Austenitic) stainless steels and Ni - base super alloys. The need for machining of the components is reduced to a minimum and welding during final assembly is reduced substantially compared to conventional practice. A HIP PM valve body design offers better performance, improved service life as well as delivery time and cost advantages versus conventional manufacturing methods. Typically, Manifolds made by the HIP PM route reduce the necessary welding by 70—80 %. The driving force in the substitution from conventional forging and fabrication to HIP PM components rely on reduced manufacturing lead-time, design flexibility, improved quality and isotropic properties and an advantageous cost for the final component. The HIP PM near net shape route has received approval from ASTM, API, NORSOK and NACE. This paper will review the manufacturing sequence for PM near net shapes and will discuss details of several manifold components.