Mix Solution Providing Excellent Fillability and High Apparent Density to Improve Compaction Performance

Cost-efficient manufacturing of high-performance components requires mix solutions with high apparent density (AD) and good fillability. This is especially critical for taller and more complex-shaped components, where powder solutions with higher AD and consistent die filling are crucial. Traditionally, metal-stearate lubricants have been used to obtain high AD. However, these lubricants provide not only high AD but also often leave stains on sintered parts and residues in the sintering furnace. Höganäs’ new bonded mix solution, Starmix Nova, is developed to offer high AD and excellent filling performance without using metal stearates.This study is based on laboratory experiments and compaction trials in production environments. Compared to a standard Premix with amide wax, Starmix Nova mixes achieve 0.3 g/cm3 higher AD, equivalent to a Premix containing Zn stearate, while exhibiting faster flow and better lubrication. In production trials, Starmix Nova mixes have shown improved component-weight consistency and increased productivity