Lecture # 7

19 July 2021

Dr. A. Upadhyaya TA201P: Introduction to Manufacturing Processes

 Powder Metallurgical Processing

Dr. A. Upadhyaya TA201P: Introduction to Manufacturing Processes

KEY PROCESS STEPS

 Powder Processing

 Shaping
(by die-compaction / cold-isostatic pressing /
or by Powder Injection Moulding)

 Sintering
(by solid-state or liquid-phase sintering)
Schematic of P/M Process
Powders
Lubricants/
Premix Operation Alloying

Compaction

Sintering

Secondary Operations

Finished Component
 Powder Metallurgical (P/M) Processing
Advantages
 Only technique for manufacturing refractory metals and ceramics
 Net-shape manufacturing process
 High dimensional accuracy and precision achieved
 99.9% material utilization, negligible amount of scrap
 Relatively cleaner (environmentally-friendly) process
 High production rate
 Ease of automation
 Can tailor novel compositions
 Homogenous microstructures lead to homogeneous properties
 Better durability product due to ability to engineer microstructure
and better control over defects
Certain compositions (e.g. Cu-Pb alloy) not possible to

process by casting (due to immiscibility between Cu and Pb)

can be used for fabricating components through Powder

Metallurgy (by mixing both powders in their elemental form

and then shaping it by pressing and subsequently sintering

the compact)
 Powder Metallurgical (P/M) Processing
Limitations

• It is difficult to produce certain shapes with powders having very poor

flowability.

• Some metals are difficult to press due to their tendency to stick to the
die during high pressure.

• Expensive dies and toolings limit the size of parts produced.

• Not economical for small-scale production.

• The parts fabricated by PM can be brittle if not sintered properly

• Powders with high vapour pressure (e.g. Zinc) not possible to sinter.
Powder size, shape and microstructure depends on
the type of preparation technique used.
Gas Atomization
 Powder Fabrication Techniques
Reduction
e.g. reduction of Fe3O4 to get ‘sponge’ Fe powder. It has internal porosity
Milling
e.g. Ti powder. Milled ductile powders have often ‘flaky’ morphology
Variant: Mechanical Alloying used for making ‘alloy powders’ by milling
various constituent powders together
Electrolysis
e.g. electrolytic Cu powder. Has ‘dendritic’ morphology

Atomization of alloy/metal melt

Water Atomization:
use water jet to disintegrate melt into small droplets that solidify to form powder. The
powders are irregular shaped. Similar to reduced powder, but have no internal porosity

Gas Atomization:
use inert gas to disintegrate melt. The powder has rounded/spherical shape
 Powder size, shape and microstructure depends on
the type of preparation technique used.

Milled Ti Powder Electrolytic Cu Powder

Powder Fabrication Route: Milling Electrolysis

 Effect of Processing Technique on Shape and Structure of Iron Powder
• atomized

• reduced

x 200 x 400

supplier: Kawasaki Steel

Powder Preparation Powder Shape
Technique

Milling Flat powder with Angular morphology

(flaky powder)

Reduction Irregular shape with internal porosity

(spongy powder)

Water atomization Irregular powder with no internal porosity

Gas atomization Rounded powders (gas atomized powders

are smaller than water-atomized powders)

Electrolysis Dendritic morphology

Compaction of Powders
SINTERING
Thermal treatment for bonding particles together
into coherent, solid structure via mass transport
events that occur largely at the atomic level.

The bonding during sintering causes lowering the

overall energy of system during sintering and leads
to improvement in strength.
SINTERING
Thermal treatment for bonding particles together
into coherent, solid structure via mass transport
events that occur largely at the atomic level. The
bonding during sintering causes lowering the
overall energy of system during sintering and leads
to improvement in strength.
Variants:
Solid-State Sintering
Liquid Phase Sintering
SINTERING
Thermal treatment for bonding particles together into coherent, solid
structure via mass transport events that occur largely at the atomic level

Loose powder Initial stage Intermediate Final stage

• Point contact • formation of stage
• Formation of
necks between • Pore rounding
few isolated,
Particles • Densification, spherical pores
• Pores are angular and
• Enlarged grains
• Grain growth

R.M. German, Powder

R.M. German, PowderMetallurgy Science,
Metallurgy Science, MPIF, MPIF, Princeton,
Princeton, NJ, USA, 1994
NJ, USA, 1994
Effect of sintering time on densification of monosized, spherical Cu powder.
Note that as the sintering time increases (temperature is constant: 1000°C), porosity gradually reduces.
In case the sintering time is kept the same, similar results can be achieved by increasing the sintering temperature
Solid-State Sintering of W Powder Compact

initial intermediate final

• W powder size:
6 µm
• green density:
58% of theoretical density
• sintering temp.:
1750°C
• sintered density:
90% of theoretical density
sintered

as-pressed
 Effect of Sintering Temperature on Densification in Copper

Sintered at 840°C

Sintered at 700°C

Green
 WC-Co Alloys (Cemented Carbides) Drill-bits

Green Sintered

Self-Similar Volumetric Shrinkage during Processing (Sintering)

Pressureless Sintered Filters Cu Filter
 Poor Sintered and Full-Density Sintered Microstructure

50µm 50µm
pore

10 mm
E.R. Tagore, A. Upadhyaya, A.V. Pathak, IEEE Transactions: Electronics Packaging Manufacturing, 2008, v. 31, n. 3, pp. 260-265.
axio-symmetric ceramic cutting tools fabricated
using press and sintering route
axio-symmetric components fabricated using
press and sintering route
How to fabricate non axio-symmetric objects?

heat spreader heat sink microelectronic packages

 Powder Injection Molding (PIM)

• PIM is a material forming process which incorporates the

advantages of powder metallurgy with the design flexibility
of plastic molding process.

• Depending on the powder used, PIM is sub-classified into

Metal Injection Molding (MIM) and Ceramic Injection
Molding (CIM).

• PIM is ideally suitable for producing complex-shaped,

small parts.

• It is a net-shape process with nearly complete material

utilization of metallic or ceramic particulates.
Schematic Diagram of the processing steps in PIM
Schematic Diagram of the processing steps in PIM
Injection Molded Austenitic Stainless
Steel Wrist-Watch Strap

10 mm
 Comparison of MIM Gun/Rifle Component Fabricated using Various Techniques

PIM/MIM Pressing
Parameter + + Casting Machining Stamping
Sintering Sintering
Density 98% 86% 98% 100% 100%
Tensile Strength High Low High High High

Surface Finish High Medium Medium High High

Miniaturization High Medium Low Medium High

Thin Wall
High Medium Medium Low High
Capability
Complexity High Low Medium High Low

Design Flexibility High Medium Medium Medium Low

Production
High High Medium Med-High High
Quantity
Range of
High High Med-High High Medium
Materials
Affordability High High Medium Low High
Materials for Aero‐Engines
 MIM Compressor Vane
Source:
S. Sikorski, “Metal Injection Molding for Superalloy Jet Engine Components,” MTU Aero-Engines GmbH, Germany, 2006.
A.D. Russell, “Manufacturing Gas Turbine Compressor Components by Metal Injection Moulding,” 2015.
I. Shuji and S. Shigeyuki,“Development of Metal Injection Molding Process for Aircraft Engine Part Production,” IHI Corp., Japan, 2016.
Comparison of as-injection moulded (left) and after-sintering
(right) compressor vane fabricated through PIM
Possible defects in PIM compacts after debinding
Liquid-Phase Sintering
1 or more solid
phases +
liquid phase
during
sintering

Add binder,
compaction
Cold press,
CIP

Binder burnout

Sintering
facilitated by
the liq. phase
• Effect of prolonged liquid sintering of an alloy

50 µm
 Non-Wetting System
• Al-40Sn
• 550°C, 1h in N2

Sn (melt) does not wet Al and hence ‘sweats’ out

 Use of Powder Metallurgy in Cutting Tool Industry

Earlier, high speed steel (HSS) which was manufactured by casting route was used for cutting applications. Such steels are
called cutting tool steels. However, they cannot be used by cutting at high speeds wherein the temperature can exceed 600°C.
For still higher cutting output, hardmetals or cemented carbides [WC-(6-10 wt.%)Co] is used. Such alloys are consolidated by
liquid phase sintering.
Use of Powder Metallurgy in Automotive Industry