Powder Metallurgy

Powder Metallurgy
Powder metallurgy is the process of blending fine powdered materials,
Compacting the same into a desired shape or form in side a mould
followed by heating of the compacted powder in a controlled
atmosphere , referred to as sintering to facilitate the formation of
bonding of the powder particles to form the final part.

Why Powder Metallurgy

•Cost effectiveness
Powder Metallurgy is the most cost effective of a number of possible
options for making the part.

•Uniqueness
Some characteristic of the product (e.g. combination of chemical
constituents, control over microstructure, control over porosity etc.)
can be created by starting from a powder feedstock, which would be
very difficult or sometimes impossible in conventional processing.
powder metallurgy process

(1) Powder manufacture,

(2) Blending of powders,
(3) Compacting of powders in a mould or die,
(4) Sintering.
RAW MATERIALS => Powder; Powders can be pure elements, pre-alloyed
powders.

Methods for making powders – Atomization: Produces powders of both

ferrous and non-ferrous powders like stainless steel, superalloys, Ti alloy
powders;
Reduction of compounds: Production of iron, Cu, tungsten, molybdenum;
Electrolysis: for making Cu, iron, silver powders.
BLENDING
Powders along with additives are mixed using mixers Lubricants are added
prior to mixing to facilitate easy ejection of compact and to minimize wear of
tools; Waxes, metallic stearates, graphite etc.
Powder characterization – size, flow, density, compressibility tests
Compaction: compaction is performed using dies machined to close
tolerances Dies are made of cemented carbide, die/tool steel; pressed
using hydraulic or mechanical presses.

The basic purpose of compaction is to obtain a green compact with

sufficient strength to withstand further handling operations
The green compact is then taken for sintering Hot extrusion, hot
pressing, hot isostatic pressing => consolidation at high temperatures.
Sintering: Performed at controlled atmosphere to bond atoms
metallurgically; Bonding occurs by diffusion of atoms; done at 70% of
abs. melting point of materials.

It serves to consolidate the mechanically bonded powders into a

coherent body having desired on service behavior Densification occurs
during the process and improvement in physical and mechanical
properties are seen Furnaces – mesh belt furnaces (up to 1200°C),
walking beam, pusher type furnace, batch type furnaces are also used
Protective atmosphere: Nitrogen (widely used)
ADVANTAGES AND APPLICATIONS

 Virtually unlimited choice of alloys, composites, and associated

properties
 Refractory materials are popular by this process

 Controlled porosity for self lubrication or filtration uses

 Can be very economical at large run sizes (100,000 parts)
 Long term reliability through close control of dimensions and
physical properties
 Wide latitude of shape and design
 Very good material utilization
END
welding
There are many definitions of a welding process. But the most comprehensive
definition is Welding is a fabrication process to make high strength joint between
two or more parts by heating to their melting temperature, with or without the
application of pressure and with or without the use of filler metal. The filler metal
has a melting point approximately same as the base metal.
Types of Welded Joints
• Butt joint • Lap joint
• Corner joint • T joint
• Edge joint
Welding positions
welding defects and remedies
welding defects and remedies
Classification of welding processes:

1: Gas Welding
2: Arc Welding
3: Resistance Welding:

4: Solid State Welding:

5: Thermo Chemical Welding

6: Radiant Energy Welding