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Powder Metallurgy
Powder Metallurgy
Powder Metallurgy
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Powder Metallurgy (PM)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Why Powder Metallurgy is
Important
PM parts can be mass produced to net shape or near
net shape, eliminating or reducing the need for
subsequent machining
PM process wastes very little material - ~ 97% of
starting powders are converted to product
PM parts can be made with a specified level of
porosity, to produce porous metal parts
Filters, oil‑impregnated bearings and gears
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
More Reasons Why PM is
Important
Certain metals that are difficult to fabricate by other
methods can be shaped by powder metallurgy
Tungsten filaments for incandescent lamp bulbs
are made by PM
Certain alloy combinations and cermets made by PM
cannot be produced in other ways
PM compares favorably to most casting processes in
dimensional control
PM production methods can be automated for
economical production
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Limitations and Disadvantages
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
PM Work Materials
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Collection of PM Parts (courtesy
of Dorst America, Inc.)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Engineering Powders
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Measuring Particle Size
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Screen Mesh for Sorting Particle
Sizes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Particle Shapes in PM
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Interparticle Friction and
Powder Flow
Friction between particles
affects ability of a powder
to flow readily and pack
tightly
A common test of
interparticle friction is the
angle of repose formed by
a pile of powders poured
from a narrow funnel
Larger angles mean
greater interparticle friction
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Observations About
Interparticle Friction
Smaller particle sizes generally show greater friction
and steeper angles
Spherical shapes have the lowest interpartical friction
As shape deviates from spherical, friction between
particles tends to increase
Easier flow of particles correlates with lower
interparticle friction
Lubricants are often added to powders to reduce
interparticle friction and facilitate flow during pressing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Particle Density Measures
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Packing Factor = Bulk Density
Divided by True Density
Typical values for loose powders are 0.5 to 0.7
If powders of various sizes are present, smaller
powders fit into spaces between larger ones
Thus higher packing factor
Packing can be increased by vibrating the powders,
causing them to settle more tightly
Thus higher packing factor
Pressure applied during compaction greatly
increases packing factor of powders
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Porosity
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Chemistry and Surface Films
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Production of Metallic Powders
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Gas Atomization Method
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Water Atomization Method
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Iron Powders for PM
Iron powders
produced by
water atomization
(photo courtesy of
T.F.Murphy and
Hoeganaes
Corporation)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Conventional Press and Sinter
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Conventional PM Production
Sequence
(1) Blending, (2) compacting, and (3) sintering
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Blending and Mixing of Powders
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Compaction
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Conventional Pressing in PM
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
450 kN (50‑ton)
hydraulic press for
conventional
pressing of PM
parts (photo
courtesy of Dorst
America, Inc.).
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sintering
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Sintering Sequence on a
Microscopic Scale
(1) Particle bonding initiated at contact points; (2) contact
points grow into "necks"; (3) pores between particles are
reduced in size; (4) grain boundaries develop between
particles in place of necked regions
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Densification and Sizing
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Alternative Pressing and
Sintering Techniques
Conventional press and sinter sequence is the most
widely used shaping technology in powder metallurgy
Some additional methods for producing PM parts:
Isostatic pressing - hydraulic pressure is applied
from all directions to achieve compaction
Powder injection molding (PIM) - starting polymer
has 50% to 85% powder content
Polymer is removed and PM part is sintered
Hot pressing - combined pressing and sintering
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Materials and Products for PM
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
PM Materials –
Elemental Powders
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
PM Materials –
Pre-Alloyed Powders
Each particle is an alloy comprised of the desired
chemical composition
Common pre-alloyed powders:
Stainless steels
Certain copper alloys
High speed steel
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
PM Products
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e