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WINTER 2018
Assignment 3
(03/21/2018)
Total Points: 25
1. Iron powder (theoretical density 7.86 g/cm3) is lubricated with 1 wt.% zinc stearate powder
(theoretical density 1.09 g/cm3) in a double-cone mixer. Calculate the theoretical density
of the mixture. Assume uniform mixing. [Points: 5]
2. The green density for a stainless steel powder compact is targeted at 6.5 g/cm 3. The
apparent density of the powder is 2.7 g/cm3. What is the compression ratio? [Points: 3]
3. What merit would be there forming steel compacts by pressing mixed iron (Fe) and
graphite (C) powders rather than using pre-alloyed powders? [Points: 4]
4. An irregular copper (Cu) powder (-200 mesh) is compacted and measured for green
properties. The results of the study are shown below. [Points: 8]
0 12.2 -
25 24.7 -
70 45 4.3
[A] Select a model for green density dependence on the compaction pressure and perform
a graphical fit to the data. Explain the observed fractional density dependence on the
compaction pressure and suggest probable mechanisms.
[B] What is the approximate apparent density of the Cu powder?
[C] For handling of compacts made out of these powders, in subsequent operations, if the
green strength requirement is 38.5 MPa, then estimate the green density of the compact.
[D] Estimate the porosity of the compact (corresponding to the above green density).
Suggest at least one way to reduce the porosity.
5. Compact density below a pressure drop of 50% is considered unacceptable for hard
powder such as 5 μm molybdenum (Mo). The friction coefficient (μ) with the die wall is
~0.3 while the radial to axial pressure ratio (k) is 0.5. Estimate the maximum allowable
height of a compact (1 cm diameter) in (a) single action pressing/compaction and (b)
double-action pressing/compaction. [Points: 5]