Sintering of Copper and Copper-Zinc Combination
G. Bayno, C. Magaoay, G. D. Manalo. I. H. Ilog
Department of Mining, Metallurgical and Materials Engineering
University of the Philippines, Diliman
Abstract
G. Bayno C. Magaoay, G. D. Manalo. I. H. Ilog. Sintering of Copper and Copper-Zinc Combination Page 1 of 6
The study is concerned with the determination of the Hardenability of the AISI 4140 Steel
Sample through Jominy End Quench Test. In particular, the researchers would like to come up with
the Ideal Critical Diameter DI since this signifies the existence of 50% Martensite and 50% Pearlite at
the center of the sample through an ideal quench. Ideal quenching would mean elimination of the
rate of cooling. The derived Ideal Critical Diameter is 5.39 inches which deviated 23.34% from the
theoretical due to possibility of reaustenization during the grinding done after quenching. It should
be properly noted that grinding should be done as light as possible just enough to scrap the extra
metal from the sample and not cause microstructural changes within the sample since this would
cause errors. There are also limitations with respect to the usability of the Jominy End Quench Test
especially for cases when high alloy concentration is in the sample since they would tend to increase
hardenability.
1. Introduction The samples were pelletized by the use of a mold press
of 5000ksi. The pellets were then put to a cold mount
allowing it to dry to form a base material to ease the
ISO defines sintering as, “the thermal treatment of a handling of the samples.
powder or compact at a temperature below the melting
point of the main constituent, for the purpose of increasing
2.3 Microstructure Viewing and Vickers Hardness
its strength by bonding together of the particles.”[1]
Measurement
The consolidation of a mass of powder is usually The samples were grinded, polished and etched as a
performed in a closed die, although other means such as preparation for microstructural viewing under the
roll compaction, isostatic compaction, extrusion or forging microscope. Vickers Hardness Readings were taken at two
can be used. Parts can also be produced by slip casting trials for the vertical and horizontal diameter.
using the techniques employed in pottery making.
Regardless of the technique employed, each produces
densification of the powder mass that can be related to the
density of the solid metal at its upper limit.
3. Results and Discussion
Most granular copper powder is used in the production of
P/M parts, and, generally, a closed die is used to form a Pure Copper Hardness
specific shape. As pressure is applied, the operation Temp/Time 20 mins 40mins 80mins
proceeds in a series of stages: (1) slippage of the particles 900 6.97E+10 6.75E+10 5.17E+10
with little deformation, (2) elastic compression of contact
points between particles, (3) plastic deformation of these 1000 5.04E+10 5.19E+10 5.89E+10
points to form contact areas of gradually increasing size Table 1. Pure Copper Vickers Hardness
and (4) massive deformation of the entire powder mass.
[2A]
(90-10) Copper-Zinc Hardness
To achieve uniform densification it is necessary to select Temp/Time 20 mins 40mins 80mins
a particle-size distribution which will permit uniform 900
packing in the die. It is also necessary to select suitable 1000 5.90E+10 3.03E+10
pressing conditions. Table 2. (90-10) Copper-Zinc Vickers Hardness
Different materials require different compacting
pressures. Pure copper P/M parts are produced with
relatively low pressures. An initial compacting pressure of
34- 40 ksi (234-276 MPa)* has been recommended for thin
sections although higher pressures can be used for heavier
sections. [2B] The objective is to permit the escape of gases
and water vapor formed by the internal reduction of oxides
during sintering. Compacting pressures that are too high
will prevent proper sintering of the center of the compact
and reduce the electrical conductivity and the strength. [2]
The experiment aims to give the students knowledge
about sintering process, advantages and limitations. Vickers
Hardness Test and microphotographs are also taken to
correlate the hardness readings with the microstructure of
each sample.
2. Methodology
Graph 1. Pure Copper Hardness vs. Time @ 900 ◦C
2.1 Sample Preparation
Powders of copper and zinc were weighed, one sample
consist of pure copper and another is a (90-10) copper to
zinc mixture.
2.2 Pelletizing and Cold Mounting
Figure 1: 20mins, 900 C, Cu
Figure 2: 20mins, 1000 C, Cu
Graph 2. (90-10) Copper-Zinc
Hardness vs. Time @ 1000°C
Tables 1 and 2 shows the data obtained from testing the
hardness of the different samples. Graphs 1 and 2 represent
the hardness of the pure copper sample at a constant
temperature thru time of heat treatment. We can observe
from the graph that as the time of heat treatment increases
the hardness values decreases at 900° C temperature. Vice
versa from graph 2 which is the opposite result.
Higher temperature favors the formation of a compact
structure basing from the difference of the two graphs. The
type of sintering performed is a solid phase sintering an
ethanol binder is added for compacting stability. Sintering Figure 3: 80mins, 1000 C, Cu
is the bonding of particles in a mass of powder by atomic or
molecular attraction in the solid state through the Figures: 1, 2 and 3 shows the microphotograph of the
application of heat. Powders differ from massive metals in pure copper. The trend is that the higher the temperature
having a much greater ratio of surface area to volume. and the longer the heat treatment the lesser voids and pores.
Consequently, the surface energy is greater. During The principal goal of sintering is the reduction of compact
sintering, changes in the shapes of the pores and a reduction porosity.
in their volume reduces the surface energy.
Solid Phase Sintering can be considered to proceed in
three stages. During the first, neck growth proceeds rapidly
but powder particles remain discrete. During the second,
most densification occurs, the structure recrystallizes and
particles diffuse into each other. During the third, isolated
pores tend to become spheroidal and densification
continues at a much lower rate.
Figure 4: 20mins, 1000 C, CuZn
4. Conclusion and Recommendation
The Ideal Critical Diameter (DI) for the AISI 4140 steel
Figure 4 and 5 is a photomicrograph of (90-10) CuZn sample acquired is 5.39 while the theoretical value is 4.37.
mixture. In liquid phase sintering a mixture of two or more One possible source was already tackled in the Results and
powders is sintered at a temperature below the melting Discussion part. However, errors can also be accounted for
point of the high-melting constituent but above that of the the uneven surface of the sample being processed including
low-melting constituent. the base. The effect of such an uneven metallographic
surface is on the hardness reading that would tend to be
Liquid phase sintering applies to premixed powders of lower for depressions and higher for protrusions. As for the
copper-tin and iron-copper, for example. If the constituents base, unevenness would cause unwanted twisting of the
are properly mixed, the behavior on sintering depends on sample which would cause hardness errors. It is
the wetting properties of the two metals. The mechanism of recommended that caution in grinding be emphasized to
liquid phase sintering can be explained by considering three refrain from possible reaustenization of the sample which
overlapping actions: (1) the liquid phase allows would make erroneous contributions to the sample and later
rearrangement and rapid shrinkage of the solid material, (2) the Critical Diameter that will be computed.
dissolution and re-precipitation occur with accompanying
densification and (3) coalescense occurs when the liquid
phase disappears. [3]
Figure 5: 40mins, 1000 C, CuZn
6. Appendix
Table1. Raw Jominy End Quench Data
DQE (inches) HARDNESS
0 -
5. References
0.0625 46.33333333
[1] [Link] Metallurgy - Sintering and Sintering 0.125 45.33333333
[Link] 0.1875 43.5
[2] [Link] Powder Metallurgy - Copper Powder 0.25 48.16666667
Consolidation [Link]
0.3125 47.66666667
[2A] P.J. James, "Fundamental Aspects of the
Consolidation of Powders," Powder Met. Int. 4:82 (1972). 0.375 45.33333333
[2B] P.W. Taubenblat, W.E. Smith and C.E. Evans, 0.4375 46.33333333
"Production of P/M Parts from Copper Powder," Precision 0.5 45
Metal 30(4):41 (1972).
0.5625 46.5
[3] F. Thummler and W. Thomma, "The Sintering
Process," Metallurgical Reviews No. 115, June (1967). 0.625 46.33333333
0.6875 44.66666667
0.75 47
0.8125 43.33333333
0.875 43.33333333
0.9375 41
1 41.33333333
1.125 40.66666667
1.25 39.16666667
1.375 37.33333333
1.5 35
1.625 33.5
1.875 33.5
2 32
2.25 31
2.5 31.66666667
2.75 32.33333333
3 31.66666667
3.25 30.5
3.5 31
3.75 32
4 -
Graph1. Jominy End Quench Test Data for Different
Alloys