Pulverization

Powder
Metallurgy
1
Manufacturing method to produce components by bringing a powder of the metals as
starting material into desired end shape.
Powder Metallurgy
The essential feature is that the bond between particles is produced without total melting
2
In powder metallurgy, the metal or alloy is solid at the very start of manipulation and
remains completely solid during the manipulation process .
3
Where/why we need powder metallurgy?
4
Refractory Metals
Composite Materials
Porous Materials
Structural parts
Special high-duty alloys
5
Refractory Metals
Very high melting points.
Very difficult to produce by melting and casting
Frequently brittle at cast state.
Ex: Tungsten, Molybdenum, Tantalum & related metals/alloys.
6
Composite Materials
Two or more metal which are insoluble even in liquid state.
Mixture of metals with non-metallic substance

(oxides & other refractory materials)
7
Composite Materials
Examples :
Electrical contact materials (Cu/W, Ag/CdO).
Hard metals ( WC3, Ni, Ni-Co, Ni-Cr based Super alloys).
Diamond Cutting tools (small diamond powders uniformly distributed in a metal

matrix)
8
Porous Materials
Examples:
Filters and oil retaining bearings. (need controlled porosity)
Above products cannot readily or satisfactorily be produced by alternative processes.
9
Special high-duty alloys
High speed steels , Super alloys based on Ni &/or Cr.
Advantage of use of PM
Higher yield
Uniform Micro-structure
10
Structural parts
Iron based parts but significant amount of copper, brass, bronze & Al
Some rare metals such as beryllium & Titanium
Do not have properties superior to other techniques (forging or machined

wrought bars) but adequate.
11
Powder Metallurgy
Required conditions
The powders in which the basic materials are available must be capable of sufficiently
close packing under pressure.
in the case of alloying, be capable of being sufficiently intimately mixed.
It must be possible to form a continuously bonded matrix.
12
Basic Operations
The preparation or manufacture of powder.
Pressing or compacting of powders.
Heating the compacts (sintering)
Post-Sintering processes (repressing, case hardening, etc)
13
Powder Production Techniques
Pulverization
Atomization.
Electrolytic deposition
Reduction of metal oxides
14
Pulverization
(Comminution, Crushing & grinding)
Compressive , shear or impact
Process of applying an external force to a (solid) material of a certain size to destroy it

and reduce it into pieces that are smaller than the original size
15
Pulverization
Dry Pulverization Wet Pulverization
Pulverize in air or inert gas Pulverized in liquid such as water
Pulverization into particles of various sizes Pulverization target is fine particles

ranging between large and fine is possible and ultrafine particles
It is unlikely that particle diameter is The ultimate particle size can reach
reduced to 3 μm or less –> the so-called “3 nm order
μm barrier”
High cost compared to dry
Low cost compared to wet pulverization pulverization
Can have more contaminants than dry

pulverization 16
Classification of Pulverization
Pulverization Operation Output size Main pulverization Examples of pulverizer

(ground particle size) mechanism
Crushing m order ⇒10cm or less Compression Jaw crusher
Gyratory crusher
Medium crushing 10cm ⇒ 10mm or less Compression Crushing roll
Impact and shear Hammer mill
Roller mill
Grinding / milling 1mm ⇒ 10μm or less Impact Jet mill
Friction Ball mill
Shear Vibratory ball mill
compression Planet mill
Ultrafine grinding 10μm ⇒1μm or les Impact, shear, and friction Wet medium agitation type
compression grinder
(bead mill)
17
Crushing
Jaw crusher
18
Crushing
Gyratory crusher
19
Medium crushing
Crushing roll
20
Medium crushing
Hammer milling
21
grinding / milling
Ball milling
22
grinding / milling
Vibratory ball milling
23
Grinding / milling
Jet Milling
24
Ultrafine grinding
Bead mill
25
Pulverization
Successfully applied to relatively hard and brittle metal
Advantage
Ability of producing very fine particles
Disadvantage
Possible contamination of the powder.
Oxidation of the newly produced powder surfaces.
26

Pulverization

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Powder

Special high-duty alloys

Very high melting points.

Very difficult to produce by melting and casting

Frequently brittle at cast state.

Ex: Tungsten, Molybdenum, Tantalum & related metals/alloys.

Two or more metal which are insoluble even in liquid state.

Mixture of metals with non-metallic substance

Electrical contact materials (Cu/W, Ag/CdO).

Hard metals ( WC3, Ni, Ni-Co, Ni-Cr based Super alloys).

Diamond Cutting tools (small diamond powders uniformly distributed in a metal

Filters and oil retaining bearings. (need controlled porosity)

Above products cannot readily or satisfactorily be produced by alternative processes.

High speed steels , Super alloys based on Ni &/or Cr.

Some rare metals such as beryllium & Titanium

Do not have properties superior to other techniques (forging or machined

in the case of alloying, be capable of being sufficiently intimately mixed.

It must be possible to form a continuously bonded matrix.

The preparation or manufacture of powder.

Pressing or compacting of powders.

Heating the compacts (sintering)

Post-Sintering processes (repressing, case hardening, etc)

Reduction of metal oxides

(Comminution, Crushing & grinding)

Compressive , shear or impact

Process of applying an external force to a (solid) material of a certain size to destroy it

Dry Pulverization Wet Pulverization

Pulverize in air or inert gas Pulverized in liquid such as water

Pulverization into particles of various sizes Pulverization target is fine particles

Can have more contaminants than dry

Pulverization Operation Output size Main pulverization Examples of pulverizer

Vibratory ball milling

Ability of producing very fine particles

Possible contamination of the powder.

Oxidation of the newly produced powder surfaces.

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