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Study of processes for manufacturing of valve seats and valve guides through
powder metallurgy

Conference Paper · June 2018

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 International Conference on Mechanical Industrial System Engineering (ICMISE’2018), Graphic Era Deemed
to be University, Dehradun, 1st 2nd June’2018

Study of processes for manufacturing of valve seats and valve guides

through powder metallurgy
1 2 3
Anurag Singh , Rishabh Kohli and Gagan Bansal
1,2
Graduate Student, Graphic Era deemed to be University Dehradun, INDIA

3
Assistant Professor Graphic Era deemed to be University Dehradun, INDIA

Abstract. In the present work, the processes used to manufacture a valve seat and valve guides arestudied. The powder material is
made by blending the iron powder(base) with different powders like manganese sulphide,acrawax etc to achieve different properties.
The powder is then takenfor compaction process where it gets its shape by the high-pressure machines. These productsare then
sintered in a furnace with copper. Then different processes are used to improve theproperties (hardness, wear resistance) of the
materials. The final comes the quality check tosee how much the product can withstand without failure. This article presents the
differentprocesses and methods used to make a valve seat and valve guides.

Keywords: Powder Metallurgy, valve seat, valve guide lines, manufacturing process, Quality Testing

by the cooling system. Bronze is commonly used, as

1 INTRODUCTION steel; a balance between stiffness and wear on the valve is
essential to achieve a useful service life.
1.1 VALVE SEATS:
The Valve Seat in an internal combustion engine
2 PROCESS INVOLVED:
(gasoline or diesel) is the surface against which an intake
or an exhaust valve rests during the portion of the engine
 2.1 BLENDING PROCESS:
operating cycle when that valve is closed. The valve seat
Blending of powders is defined as the through
is a critical component of an engine in that if it is
intermingling of powders of the same nominal
improperly positioned , oriented , or formed during
composition. The implication with blending is that the
manufacture, valve leakage will occur which will
constituents in the vessel are virtually identical except for
adversely affect the engine compression ratio and
some minor physical characteristics.
therefore the engine efficiency , performance
Blending Process comes from powder metallurgy is a
(horsepower) , exhaust emissions , and engine life.
term covering a wide range of ways in which materials or
components are made from metal powders. Power
1.2 VALVE GUIDES:
metallurgy is also used to make unique materials
In most type of reciprocating engines, a valve guide is impossible to get from melting or forming in other ways.
provided for each poppet valve in the cylinder head. Different powders are brought for different components
Along with the valve spring, it serves to positively locate depending upon the area of use. Basically for valve seats,
the valve so that it may make proper contact with the the following powders are mixed;
valve seat. A valve guide is cylindrical piece of metal, 1. Base Iron Powder (maximum weight)
pressed or integrally cast into the cylinder head, with the 2. Manganese Sulphide (MnS)
valve reciprocating inside it. Guides also serve to conduct 3. Acrawax (Lubricant)
heat from the combustion process out from the exhaust
valve and into the cylinder head where it may be taken up
18
ICMISE 2018
And Basically for valve Guides, the following powders
are mixed:
1. Iron Powder
2. Graphite
3. Copper
4. MolybednumDisulfide(MOS2)
5. Calcium Carbonate(CaCO3)
6. Kenolube
2.2POWDER COMPACTION:
After the Blending Process, the powder came for
compaction. Powder Compaction is the process of
compacting metal powder in a die through the application 
of high pressure. Typically, the tools are held in the
vertical orientation with the punch tool forming the
bottom of the cavity. The powder is then compacted into
a shape and then ejected from the die cavity. In a number
of these applications the parts may require very little
additional work for their intended use, making for very
cost efficient manufacturing. The pressure of 10 to 50
tonne is commonly used for metal compaction. Dorst 50
tonne machine is used for powder compaction. They
contain different punch for different purpose, some are 
single punch & some have multiple punches. These
machines are used for valve seats. For valve guides, there
are different machines which work on 150 tonne and 200
tonnes maximum. The working of the machine of valve
guide is quite similar to the working of the machine of
valve seat but the punches are different and have their
different functions.
2.3 SINTERINGPROCESS:
Sintering is the process of compacting and forming a
solid mass of material by heat or pressure without
melting it to the point of liquification.
The atoms in the material diffuse across the boundaries of
the particles, fusing the particles together and creating
one solid piece. Sintering process is done with the help of
furnace. Copper rings which are made by same
compaction process but with the copper powder only are
placed below the valve seats. Valve seats are made with
the powder metallurgy causes the piece to be porous.
These pours are filled by the copper with the help of the
sintering process.
2.4 CRYOGENIC TREATMENT:
19
A cryogenic treatment is the process of treating work
pieces to cryogenic temperature’s (i.e. below -190˚C) in
order to remove residual stresses and improve wear
resistance on steels. The execution of the deep cryogenic
treatment on quenched and tempered high-speed steel
tools increaseshardness, reduces tool consumption and
down time for the equipment set up, thus leading to cost
reductions to 50%. In addition to seeking enhanced
stresses stress relief and stabilization, or wear resistance,
cryogenic treatment is also sought for its ability to
improve corrosion resistance. It increases yield strength,
corrosion resistance, multiple wear properties and coating
bond strength.
2.5 TEMPERING PROCESS:
After the cryogenic treatment, the valve seat and the
valve guide are placed for tempering process. Tempering
process of heat treating, this is used to increase the
toughness of Iron based alloy. Tempering is usually
performed after hardening to reduce some of the excess
hardness. It is done by heating the metal to some
temperature below the critical point for a certain period.
2.6 OIL IMPREGNATION:
Oil Impregnation process is used for impregnated the oil
into the whole clearance of the porous material by
capillary phenomenon. The pressure inside the oil
impregnated tank is reduced to the atmospheric pressure
or lower so that the oil is easily impregnated into the
products.
 2.7 SIZING:
The product formed by the above processes is not much
accurate (as they work in mm & CNC’s work in
microns). These machines cannot produce the accurate
size which we needed.Soto make the accurate products
CNC machines are used which make the product more
accurate for use. In Federal Mogul India Lim. There are
two types of CNC’s are used one is automatic and one is
manual. In automatic CNC, all the data is already
programmed, we only have to place the product into it. It
works muchfaster than the manual CNC. In the manual
CNC, there should be an operator present there to operate
it. And its speed of sizing the product is less in
comparison of automatic CNC.
 2.8 GRINDING:
In the grinding process, each grain of abrasive on the
wheel’s surface cuts a small chip from the work piece via
shear deformation. Grinding is used to finish workpieces
 International Conference on Mechanical Industrial System Engineering (ICMISE’2018), Graphic Era Deemed
to be University, Dehradun, 1st 2nd June’2018
that must show high surface quality(e.g. low surface
roughness) and high accuracy of shape and dimension.
In Federal Mogul India Limited, there are different types
of grinding machines are used for different grinding
process and there are some defects also:
1. 2.8.1 Side Face Grinding:
It also operates on CNC. In this company, there are two
types of CNC side face grinding machines work, one is
automatic and other is manual. The side of the product is
grinded in face grinding. And the amount of extra metal
get grinded out of the product which makes the product
which makes the product more smooth, light in weight 
and of accurate dimensions.
2.8.2 Outer Diameter Grinding:
It also operates on CNC. In this company, there are two
types of CNC side face grinding machines are available,
one is automatic and other is manual. In this process the
outer diameter of the product is get grinded by the
machine to make it more accurate, light in weight,
smooth and of more accurate dimensions. 1.
2.9 MAGNETICPARTICLE INSPECTION:
MPI is a non-destructive testing (NDT)process for
detecting surface and slightly subsurface discontinues in
ferromagnetic materials such as iron, nickel, cobalt, and
some of their alloys. The process puts a magnetic field
into the part, the piece can be magnetised by direct or
indirect magnetization. Direct magnetization occurs when
the electric current is passed through the test subject and
a magnetic field is formed in the material. Indirect
magnetization occurs when no electric current is passed
through the test object but a magnetic field is applied
from an outside source. The magnetic lines of force are 2.
perpendicular to the direction of the electric current,
which may be either alternating current (AC) or some
form of direct current (DC).
2.10 VIBRO(Vibratory Finishing Machine):
Method for surface improvement with ceramic, steel,
plastic, corn, cobb media. It is a bowl type centrifugal
finishing machine. The machine bowl is leaded with
suitable ceramic plastic or steel media and the
components be processed. The mutual rubbing action
takes place inside the chamber due to gyratory vibrations
compared to other simpler process. This method
completes the deburring process faster. It is driven by
20
powerful vibratory motor causing intense and trouble free
output.
2.11VISIBLE INSPECTION:
The one of the last process before packing, there is a
visible inspection of every single valve seat or valve
guide. The operator check the valve seat or valve guide
by itself and ensue that is there any blow hole, rust or
crack present in the product, if there is no blowhole, rust
and crack then the product is perfect and sent it for
packing. And if there is any defect than reject it.
2.12 QUALITY TESTING:
At every stage the material is brought to the quality lab
for testing. It is necessary so that if any defect in the
production is detected the process can be stopped at that
very moment and lot rejection would be easy. If the
quality person misses any defect in the lot the rejection
would be large in number afterwards.
Different machines used for quality testing are as follows:
Profile Projector: It is also known as optical comparator,
or even called a shadowgraph, a profile projector is an
optical instrument that can be used for measuring. It is a
useful item in a small parts machine shop or production
line for quality control inspection. Profile projector is
widely used for compact shape stampings, gears, cams,
threads and comparing the measured contour model. It’s
easy to use and highly efficient.
It is a commonly used measurement of optical
instruments. Thus, profile projector is widely used in
major machinery manufacturing including aviation,
aerospace industry, watches and clocks, electronics,
instrumentation industry, research institutes and detection
metering station at all levels and etc.
Spectro Xepos: SPECTRO Analytical Instruments offers
a flexible XRF spectrometer dubbed SPECTRO XEPOS,
which is specifically designed for challenging
applications. Features like intelligent software modules,
optimal excitation utilizing polarization and secondary
targets, and an autosampler for up to 12 items, make the
SPECTRO EXPOS a highly versatile element analyser.
The tool provides high precision and sensitivity for the
complete element range from Na to U. It analysis of
waste, soils and sewage sludge. Additives in slag, cement
and oil.
3 CONCLUSION
 ICMISE 2018

Based on the process study and the over view of Powder M Ashtari (2002) The role of heat treatment on
metallurgy, following Conclusions can be made: wear behavior of powder metallurgy low alloy
steels. Materials & Design 667-
1. Powder Metallurgy can form parts that would 670.doi:10.1016/S0261-3069(02)00046-8
otherwise be difficult to form.
2. The parts made by powder metallurgy have net
shape or near net shape with a high degree of
precision and repeatability.

ACKNOWLEDGEMEMNT
We would like to thank Graphic Era University,
Dehradun and our Head of Department Dr (Prof) Pravin
P. Patil for providing all sorts of amenities and support.
Also we would like to thank Federal Mogul Power Train
Company for giving us opportunity to explore.

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