POWDER METALLURGY (P/M)

• Manufacturing processes
- raw materials molten state
solid form
• another raw material powder P/M
• competitive with processes such as casting,
forging & machining.
• For relatively complex parts made of high
strength & hard alloys.
• Good dimensional accuracy, various sizes.
• Typical product - gears, cams, bushings,
automotive components. (See figure 7)
• P/M process consist:
1. Powder production
2. Blending/Mixing
3. Compaction
4. Sintering
5. Finishing operations, See figure 3
Fig 7
Fig 3
 METHODS OF POWDER
PRODUCTION
• several methods
• metal sources - bulk metal & alloys, ores, etc.
• choice of methods depending on the requirements of end product
• particle sizes range 0.1 - 1000µm
• Methods:
1. Atomization
2. Reduction - metal oxides remove O2
3. Electrolytic deposition
4. Carbonyls - metal carbonyl + CO2
5. Communication (pulverization) - crushing
6. Mechanical alloying - 2 or more metal mixed
 ATOMIZATION
• common method (see figure 17.3)
• produces liquid-metal stream by injection molten metal
through a small orifice
• stream broken up by jet of inert gas, air or water
• particles size depends on temperature, rate of flow, nozzle
size, jet characteristics.
• Other variation method
- electrode rotated rapidly in helium - filled chamber
- centrifugal forces breaks up the molten metal tip of
electrode
Figure 17.3
BLENDING/MIXING
• Reasons for mixing
1. Powders made by various processes - may have
different sizes and shapes mixed obtain
uniformity.
2. Different metallic & other materials mixed to
import special physical & mech. Properties to the P/M
product.
3. Lubricant may be mixed improve flow
characteristics reduce friction between metal particles
improved flow into dies longer die life.
• Mixed in air or inert atmosphere (avoid oxidation)
 COMPACTION
• Blended powders pressed into shapes in dies using presses
either hydraulically or mechanically activated (see figure 17.4)
• purpose - obtain required shape, density, particle-to-
particle contact
• powder must flow easily into die cavity
• density depends on the pressure applied (see figure 17.5)
• density depends on the size distribution of particles
• same size porosity (24% by volume)
• introducing small particle higher density
• density can vary considerably within the part (see
figure 17.6 and table 17.1)
use multiple punches
• Equipments - for Al 70 - 800 MPa (high
density iron parts)
- press. depends on shape of particles,
blending method & lubrication
- pressing speed consider the
entrapment of air in the die cavity
porosity
Fig 17.4
Fig 17.5
Fig 17.6
Table 17.1
• Cold Isostatic Pressing (CIP)
- metal placed in a flexible rubber mould made of
neoprane rubber, urethane or other alastomers
- pressurised hydrostastically in chamber  400 Mpa

• Hot Isostatic Pressing (HIP)

• Rolling
- powder/roll compaction
- powder fed to roll gap into two-high rolling mill
- continuous strip
- at room or elevated temperature
- typical part - sheet metal for electrical & electronic
components
• Extrusion
- powder is encased in a metal container and extruded
- reheated and forged in closed die.

• Injection Moulding
- new process
- metal powders blended with polymer
-  similar plastic injection moulding or pressure diecasting
- moulded product placed in low-tem. Oven to burn off the
plastic
sintered furnace
- fast

• Pressureless compaction
- die filled with metal powder by gravity
- sintered directly in the die
- low density
- used principally for porous parts such as filters
SINTERING
• compressed metal powder is heated in controlled -
atmosphere furnace to temperature below melting
point.
• Strength of the bond between particles
• 70 - 90% Tm.
• 10 minutes (iron & copper alloys) - 8 hrs.
(tungsten)
• Furnaces have 3 chambers
1. Burn off chamber - voltalize the lubricants
- improve bond
- prevent cracking
2. High-temp. chamber for sintering
3. Cooling chamber
Secondary and finishing operation
• to impart dimensional accuracy to the sintered part
• improve its strength & surface finish
• including
1. Heat treating for improved hardness & strength
2. Machining by milling, drilling & tapping
3. Grinding for improved dimensional accuracy & surface finish
4. Platting for wear resistance, improved appearance and
corrosion resistance.

Design Consideration
• shape kept as simple & uniform
- sharp, thin, thickness varies avoided
• provision made for ejection product damaged
• wide tolerances application
• see figure 17.9
Fig 17.9
Advantages
• wide range of compositions mech. & physical properties
• high production rate
• good dimensional control/accuracy
• capability for impregnation & infiltration for special applications
Limitations
• size & complexity
• high cost of powder
• high cost of machines
• mech. Properties generally low.