Module 5

Powder Metallurgy
 Principles of Powder Metallurgy Process

• Powder metallurgy is the process of blending fine powdered

materials, compacting the same into a desired shape or form
inside 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.
• Powder Metallurgy route is very suitable for parts that are
required to be manufactured from a single or multiple
materials (in powder form) with very high strength and
melting temperature that pose challenge for the application of
casting or deformation processes.
https://slideplayer.com/slide/10508681/
Powder metallurgy process generally consists of four basic steps
(1) Powder manufacture
(2) Blending of powders
(3) Compacting of powders in a mould or die
(4) Sintering.
Compacting is generally performed at room temperature and at
high pressure.
Often, compacting and sintering are combined.
Optional secondary processing often follows to obtain special
properties or enhanced dimensional precision.
Basic steps in Powder Metallurgy process
 Steps involved in PM technique

1. Preparation of powders: very fine powders are obtained using various

techniques.
2. Blending of powders: The fine powders are mixed along with a lubricant. The
lubricant helps in imparting good fluidity to the powders.
3. Compacting: The blended powder is compacted in a mold or die.
4. Sintering: The compacted mass is sintered at a high temperature in a furnace in
a controlled atmosphere.
5. Sizing: The sintered component is passed in a mold or dies to trim the
component and achieve high dimensional accuracy.
6. Machining: If required final machining is done on some specific locations
including drilling very small holes.
7. Treatment: Parts are subjected to deburring and tumbling to remove any small
projections and other treatments like oil impregnation tec., are given.
8.Inspection: Finally parts are inspected to check the quality .
 Production of Metal powders

• Metal powders are produced by using a variety of techniques, the

size of the particles range from 0.1 to 1000μm.
• Bulk metals and alloys, ores, and other compounds are used.
• The shape, porosity, purity, size and distribution of the particles
depends on the type of process used.

• The methods normally used for the production of metal powder are
a. Atomization.
b. Reduction
c. Electrolytic deposition
d. Pulverization
e. Mechanical alloying
f. Others
 Atomization Method
• It consists of mechanical disintegration of molten metal into fine particles
by met of a jet of compressed air or water.
• Here the liquid metal stream is produced through a small orifice and the
stream is broken by a jet of inert gas/water/air.
• Finely divided particles are obtained. The size of the particle depends on
the temperature of the metal, flow rate, nozzle size & jet characteristics.
• A continuous uniform production of metal powders can be obtained .
Rotating Electrode Method
In this method a consumable
electrode(Metal rod) is rotated
rapidly in a helium gas filled
chamber.
The centrifugal force breaks up the
molten tip of the electrode,
producing particles.
Opposite to the spindle tip a non
rotating electrode establishes an arc
which heats the metal electrode
which is rotating. Tiny droplets of
metal are formed.
Reduction Method
Electrolytic deposition
 Pulverization method

 In this method metals (brittle & less brittle) are

crushed in a ball mill to produce small particles.
 In a ball mill, using rotating hollow cylinders, partly
filled with steel or white cast iron balls, the metals
are crushed.
 Repeated rotation of hollow cylinder results in
crushing of the metal.
 Brittle metals will produce particles of angular
shapes.
 Ductile metal will produce flake particles. (Hence,
not suitable for powder metallurgy application).
Mechanical Alloy
• In this method, powders of two or more metals are mixed in
a ball mill.
• Due to impact of hard balls, the powders undergo fracture
and weld together by diffusion,forming alloy powders.
Other methods
Some of the methods which are used in addition to the
above are:
• Precipitation from a chemical solution.
• Production of fine metal chips by Machining & Vapor
deposition
Particle shapes
 Blending Metal powders
• Here powders of two or more metals having different size &
shapes are mixed to get a uniform mixture.
• The ideal mixture consists of Particles having uniform
distribution.
• Powders of different metals are mixed to improve physical &
mechanical properties as required.
• To improve the flow characteristics, lubricants are mixed with
the metal powder.
• This will insure proper filling of the dies and improves the die
life.
• About 0.25 to 5% by weight Zinc stearate or stearic acid
areused as lubricants.
• Mixing of powder must be carried out under controlled
conditions to prevent contamination
Blending Metal powders
 Compaction of Powder
 In this step, the blended powders are pressed into shapes in dies using
presses activated by hydraulic & mechanical means. The pressure is around
70-800Mpa.
 By pressing, the required shape with the desired density, with good particle
to particle contact can be obtained. The pressed powder is referred to as
green compact. Pressing is generally done at room temperature, but can
also be carried out at elevated temperature.
 The density of the green compact depends on the pressure applied.
 As the compacting pressure is increased, the density approaches that of the
theoretical density of the metal in the bulk form.
 If the size of the particles are the same then there will always be some open
spaces between the particles. This space is referred to as porosity.
 In general, the porosity will be around 24% by volume.*Introducing
smaller particles will fill the spaces between the larger particles and thus
result in a higher density of the compact.
 Higher the density, higher will be the strength and elastic modulus of the
part
 Methods of compaction
Powders are compacted by any one of the methods:
• Using a punch and a die.
• By Rolling.
• By Extrusion.
• By Injection molding.
• By Isostatic pressing
 Using punch and a Die

• Here a punch and a die

assembly is used.
• The metal powder mixture is
filled in the die and the punch
is forced on it. The powder gets
compacted.
• The range of pressure used for
compaction is shown in the
table.
 Powder Rolling
• In powder rolling (powder
compaction) the powder is fed
into the roll gap in a two high
rolling mill and is compacted
into a continuous strip at
speeds up to 0.5m/s.
• The process can be carried out
at room temperature or at
elevated temperatures.
• Sheet metal for electrical and
electronic components, coins
can be made by powder
rolling.
 Powder Extrusion

• Powders can be compacted

by extrusion.
• The metal powder is
encased in a container and
extruded.
• After sintering, preformed
PM parts may be rolled or
forged in a closed die to
their shape
 Powder Injection Moulding
• It is also called metal injection moulding.
• Very fine metal powders (<10μm ) are blended with a polymer or a
wax based binder.
• The blended mixture undergoes compaction due to pressure.
• The green compacts are heated in a oven at low temperature to burn
off plastic and then sintered in a furnace.
• Pressing can be carried out either at room temperature or at elevated
temperature.
• The powder must flow easily into the die cavity.
• The density of the green compact, depends on pressure applied
during compaction.
• By using particles of different shape, very close packing of the metal
powder can be achieved
• Higher density results in higher strength and higher elastic modulus
of the components.
Powder Injection Moulding
 Isostatic Pressing
• This type of operation is used for compaction of powders.
• The process is similar to pressing using cupped hands for
making snow balls.
• The main advantage of isostatic pressing is the absence of wall
friction as pressure is being applied from all directions.It
produces compacts of practically uniform grain structure and
density irrespective of shape.
• Two type of Isosatic pressing
– Cold Isostatic Pressing
– Hot Isostatic Pressing
 Cold Isostatic Pressing
• In cold isostatic pressing (CIP) the metal powder is placed in a
flexible mould madeof rubber or Urethane or PVC.
• The assembly is then pressurized hydrostatically in a chamber
usually using water.
• Pressures of 400 to 1000MPa are used.
 Hot Isostatic Pressing
• In Hot Isostatic Pressing (HIP) a metal powder is stressed using inert gas in a metal container.
• Pressure of 100MPa at 1000oC is used.
• Here a container made of very high melting point metal is used.
• An inert gas is used as the pressuring media.
• The main advantage of HIP is its ability to produce compacts with essentially 100% density,
good metallurgical bonding among the particles with good mechanical properties
• HIP process is relatively expensive and is used for making super alloy components for
aerospace industry.
• It is regularly used for the densification of WC cutting tools and PM tool steels. HIP is also
used to close the internal porosity and improve properties in super alloy and Ti alloy castings
for the aerospace industry.
 Sintering
• Sintering is a process wherein the compressed metal powder is
heated in a controlled atmosphere using a furnace.
• The temperature of the furnace will be slightly below melting
point of the metal powder but above the RCT.
• After sintering, the strength of the metal compact will be very
high.
• Sintering mechanisms are highly complex in nature & depends
on the composition of the metal powder and the processing
parameters.
• Normally at high temperatures the particles begins to form a
strong solid state bonding by diffusion. This results in high
strength, high density, high ductility and other properties.
• During sintering the component undergoes shrinkage as in
casting. This needs to be taken care of.
 Effects of Sintering

Sintering results in:

• Inter-particle bonding
• Dimensional changes
• Chemical changes
• Electrical property changes
• Phase changes
• Relief of internal stresses
• Alloying
 Stages of Sintering
Sintering is usually carried out at a constant temperature and time is varied to
obtain the desired results.
1) Adhesion without shrinkage
Initial bonding and neck growth occurs rapidly and very early in the
sintering process as the powder material is being heated up.
2) Densification and Grain growth stage
In this stage densification of powder takes place. As a result, most of the
shrinkage occurs in which pore rounding takes place, a network of pores is
formed and grain growth continues.
3) Elimination of last isolated and rounded pores
Spherodization of isolated pores rapidly increases here. Porosity decreases
more quickly in the vicinity of the grain. Further densification proceeds at
a correspondingly low rate.
 Advantages of Powder Metallurgy

 Virtually unlimited choice of alloys and non metallicswith

associated properties.
 A variety of metal or non metal powders can be used.
 Refractory materials are popularly processed by PM.
 Can be very economical for mass production (100,000parts).
 Long term reliability through close control of dimensions and
physical properties.
 Very good material utilization - loss of material very less.
 Minimization or elimination of Machining.
 Very good surface finish can be easily obtained.
 Limitation of Powder Metallurgy

• Initial Investment cost high

• Limited part size and complexity
• High cost of powder material.
• High cost of tooling.
• Less stronger than wrought ones.
• Fracture toughness may be low.
• Less well known process.
• Health hazard to the operator due to very fine powder being
processed.
 Applications of Powder Metallurgy
• Refractory Metals: Components made of tungsten, molybdenum
and tantalum by powder metallurgy are widely used in electric
light bulbs, fluorescent lamps, radio valves and many more.
• Refractory Carbides: Refractory carbides are used in modern
industries dealing with machine construction, instrument
construction, wire drawing mills, shearing process and mining.
• Automotive Applications: In the motor car industry, the porous
bearings include above all starters, screen wipers, sliding roofs,
vehicle dynamos, clutches, brakes and so on.
• Aerospace Applications: Tungsten parts having uniform
distribution of porosity are employed in plasma jet engines and
ion engines. Silver infiltrated tungsten with exceptional physical
and mechanical properties is used in nozzles for rockets and
missiles.