MANUFACTURING PROCESSES

ME-303

Department of Mechanical Engineering

HITEC University, Taxila Cantt

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 Powder Metallurgy
• Powder Metallurgy (PM) is a metal processing
technology in which parts are produced from
metallic powders.
• The powders are compressed into the desired
shape and then heated to cause bonding of the
particles into a hard , rigid mass.
• The compression is called pressing.
• The heating is called sintering and it is performed
at a temperature below the melting point of the
metal.
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Parts made by Powder Metallurgy

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 Advantages of PM parts
• PM parts can be mass produced to net shape
or near net shape, eliminating or reducing the
need for subsequent processing.
• The PM process itself involves very little
waste of material; about 97% of the starting
powders are converted to product.
• Owing to the nature of the starting material in
PM, parts having a specified level of porosity
can be made.

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 Advantages of PM Parts
• Certain metals that are difficult to fabricate by
other methods can be shaped by powder
metallurgy. Tungsten is an example
• Certain metal alloy combinations and cermets
can be formed by PM that cannot be produced by
other methods.
• PM compares favorably with most casting
processes in terms of dimensional control of the
product.
• PM production methods can be automated for
economical production.
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 Limitations
• Tooling and Equipment costs are high
• Metallic powders are expensive
• There are difficulties with storing and handling metal
powders
• Limitations on part geometry because metal powders
do not readily flow laterally in the die during pressing
• Allowances must be provided for ejection of the part
from the die after pressing
• Variations in material density throughout the part may
be a problem in PM

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 Engineering Powders
• A powder can be defined as a finely divided
particulate solid.
• Powders can be defined by the following
attributes
– Particle size and distribution
– Particle shape and internal structure
– Surface area

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 Particle size and distribution
• For a spherical particle only one dimension is
adequate
• For other shapes two or more dimensions are
needed.
• The most common method is using screens of
different mesh sizes
• The term mesh count is used to refer to the
number of opening per linear inch of screen.
The mesh is square.
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 Particle Size and Distribution
• Particles are sorted by passing through a
series of screens of progressively smaller mesh
size.
• The procedure of separation of powders by
size is called classification

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 Particle size and distribution
• Typical particles in powder metallurgy range
from 25 to 300 microns

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Problems

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Particle Shape & Internal Structure
• Metal powder shapes can be cataloged into
various types.
• A simple and useful measure of shape is the
aspect ratio---- the ratio of maximum dimension
to minimum dimension for a given particle.
• Pores between loose particles are called open
pores. In open pores fluids can penetrate.
• Internal voids in the structure of an individual
particle are called closed pores. They only effect
part density
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Metallic Powders

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Particle Shape & Internal Structure

• Smaller particle size and higher shape factor

means higher surface area for the same total
weight
• Smaller particle are still preferred because they
provide more uniform shrinkage and better
mechanical properties.
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 Interparticle Friction & Flow
Characteristics
• Friction affects the ability of powder to flow
readily and pack tightly.
• Angle of repose, which is the angle formed by a
pile of powder as it is poured from a narrow
funnel is used to measure this inter particle
friction
• Flow characters are important in die filling and
pressing.
• A common measure of flow is the time required
for a certain amount of powder to flow through a
standard sized funnel.
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Measuring Angle of Repose

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 Packing, Density and Porosity
• True density is the density of the true volume
of the material
• Bulk density is the density of the powders in
the loose state.
• The packing factor is the bulk density divided
by the true density.
• Porosity is defined as the ratio of the volume
of the pores in the powder to the bulk value .
• Packing factor + porosity = 1.0
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Problems

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 Problems
16.6

16.7

16.8

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 Chemistry and Surface Films
• Metallic powders are classified as either
elemental, consisting of a pure metal or pre-
alloyed, wherein each partial is an alloy.
• Surface films are a problem in powder
metallurgy because of the large area per unit
weight of metal when dealing with powders.
• The possible films include oxides, silica,
adsorbed organic materials and moisture.

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Metallic Powders

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 Production of Powders
• There are three principal methods by which
metallic powders are commercially produced
• The methods are
❑Atomization
❑Chemical
❑Electrolytic
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 Atomization
• This method involves the conversion of
molten metal into a spray of droplets
that’s solidify into powders.
• This method has a verity of variation
available.

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Atomization

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Atomization

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Metallic Powder Manufacturing

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Metallic Powder Manufacturing

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Manufacturing Powder Manufacturing

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Mixing of Metallic Powders

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 Chemical Reactions
• Chemical reduction includes a verity of
chemical reactions by which metallic
compounds are reduced to elemental metal
powders.
• A common method is by reduction of metallic
oxides
• Powders are also produced from salts
dissolved in water. This is know as
precipitation.

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 Electrolysis
• In electrolysis , an electrolytic cell is set up in
which the source of the desired metal is the
anode.
• The anode is slowly dissolved under an
applied voltage, transported through the
electrolyte and deposited on the cathode.
• The deposit is removed , washed and dried to
yield a metallic powder of very high purity

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Steps involved in Powder Metallurgy

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 The PM Process
• The conventional PM sequence consists of three
steps
– Blending and mixing of the powders
– Compaction
– Sintering

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Powder Metallurgy (Video)

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 Blending & Mixing
• Blending refers to when powders of the same
chemical composition but different particle sizes
are intermingled.
• Mixing refers to powders of different chemistries
being combined
• It is usually accomplished by mechanical means
– Rotation in a drum
– Rotation in a double cone container
– Agitation in a screw mixer
– Stirring in a blade mixer
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 Blending & Mixing
• Best results are obtained when container is 20 to 40%
full.
• Additives to mechanical powder include
– Lubricants
– Binders
– Wetting agents
– deflocculants

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 Additives for powders
• Lubricants to aid mold release and to reduce
internal friction between particles during molding
• Binders for the ceramic particles
• Wetting agent to improve mixing
• Deflocculents to make the ceramic water
suspension more uniform. Deflocculation
changes the electrical charges on the particles of
clay, so that they repel rather than attract each
other.
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 Compacting
• In pressing opposing punches squeeze the
powders contained in a die.
• The work part after pressing is called a green
compact.

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Compacting

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 Isostatic Pressing
• In isostatic pressing, pressure is applied from all
directions against the powders that are contained in a
flexible mold.
• It can be cold isostatic pressing, which is performed at
room temperature
• This give uniform density, less expensive tooling and
greater applicability to shorter production runs.
• Hot isostatic pressing is carried out at high
temperatures and pressures.
• Pressing and sintering can be achieved in a single step.

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Isostatic Pressing

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Cold Isostatic Pressing

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Hot Isostatic Pressing

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Hot and Cold Isotatic Pressing

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 Sintering
• Sintering is a heat treatment operation usually
carried out at temperatures between 0.7 and 0.9
of the metals melting point.
• Also called solid state or solid phase sintering.
• The heat treatment consists of three steps
– Pre heating
– Sinter
– Cool down

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Mechanism for Sintering Powder

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 Sintering

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 Sintering Atmosphere
• The atmosphere in the furnace is controlled to
– Protect from oxidation
– Provide a reducing atmosphere to remove existing
oxides
– Provide carburizing atmosphere
– Assisting in removing lubricants and binders used in
pressing
• The atmosphere can be inert gas, nitrogen based,
dissociated ammonia, hydrogen or vacuum.

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 Secondary operations
• Repressing is a pressing operation in which the part is
squeezed in a closed die to increase density and
improve physical properties.
• Sizing is the pressing of a sintered part to improve
dimensional accuracy.
• Coining is a press working operation on a sintered part
to press details into its surface.
• Impregnation is the term used when oil or other fluid is
permeated into the pores of a sintered PM part.
• Infiltration is an operation in which the pores of the
PM part are filled with a molten metal.
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Mechanical Property Comparison

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 Classes of PM parts
• Class I- simple thin shapes that can be pressed
from one side
• Class II- simple but thicker shapes that require
pressing from both sides
• Class III- two level of thickness, pressing from
both sides
• Class IV- multiple level of thickness with
pressing from both sides and separate control
for each level
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Classes of PM parts

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 Design Guidelines for PM Parts
• Economics of PM processing usually require large
part quantities to justify the cost of equipments
and special tolling required.
• Powder metallurgy is unique in its capability to
fabricate parts with a controlled level of porosity
• PM can be used to make parts out of unusual
metals and alloys
• The geometry of the part must permit ejection
from the die after pressing
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 Design Considerations
• The shape of the compact must be kept as simple
and uniform as possible.
• Provision must be made for ejection of the green
compact without damaging the compact.
• P/M parts should be made with the widest
acceptable tolerances to maximize tool life.
• Part walls should not be less than 1.5 mm thick;
thinner walls can be achieved on small parts;
walls with length-to-thickness ratios above 8:1
are difficult to press.
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 Design Considerations
• Steps in parts can be produced if they are small.
• Letters can be pressed if oriented perpendicular
to the pressing direction
• Flanges or overhangs can be produced by a step
in the die.
• A true radius cannot be pressed; instead use a
chamfer.
• Dimensional tolerances are on the order of ±0.05
to 0.1 mm.

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Design Considerations

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Design Considerations

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Design Considerations

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Design Considerations

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