Sustainable Solution for high performance PM steels: SSPM

Reasearchers: Patrick Korir and Marta-Lena Antti

The project will develop a new method to achieve high performance in low alloyed powder metallurgical steel components based on a sustainable manufacturing route. The aim is to achieve increased hardenability of structural metals for industrial applications through replacement of alloying elements and reduced CO2 footprint.

Powder metallurgy (PM) using the press and sinter method is an important process for manufacturing high performance components in large volumes. PM has several advantages; however, it faces a key challenge of achieving circularity for Fe–Cu–C materials used in PM steels. Copper (Cu) and nickel (Ni) are critical elements. Cu recovery using the current steel recycling process has proved difficult. Ni is added as an alloying element as it improves the hardenability properties of PM steels.

This project focuses on establishing a method of substituting these elements with more sustainable ones. Incorporation of chromium (Cr), manganese (Mn) and silicon (Si) yields similar properties in PM steels as Ni and Cu. The obstacle to overcome with these elements is finding the best alloying method to introduce them in PM steels since they are easily oxidized. Therefore, this project explores the master alloying (MA) route to alloy the PM steels with these elements as a preferred solution together with a suggested process route.

Sustainability aspects

The project helps to promote sustainable development by reducing the environmental impact of the manufacturing process. The focus is substitution of Ni and Cu with Mn and Cr in powder metallurgy metal powders. One key problem with the use of copper is the recyclability of components after end of life, since it is challenging to remove copper from the steel in the present steel recycling processes. Nickel, on the other hand, is associated with a large CO₂ footprint from extraction to refined form.

Additionally, there is a foreseen competition for these critical elements during the shift to electric vehicles, as they find extensive application in batteries. Substitution with chromium and manganese will make the components easily recyclable and reduce dependence on critical elements. Furthermore, Cr and Mn raw materials have a lower CO₂ footprint compared to Ni.

Project team

• Principal applicant: Marta-Lena Antti
• Industrial doctoral student: Patrick Kiprotich Korir, Höganäs AB

Project page on the WISE website

• Sustainable solution for high performance PM steels (SSPM)