P/M

(Powder Metallurgy)

Joseph Tunick Strauss

HJE Company, Inc.
Glens Falls, South Glens Falls, and Queensbury, NY

Powder Metallurgy (P/M)

Powder Metallurgy (P/M)

I
II

Introduction
General Summary of the Science of
P/M
III P/M Manufacturing Techniques
IV Applications, General Case Studies

P/M: The use of metal (or ceramic) powders in

industrial applications

Consolidation into dense parts & shapes

Structural / machine parts
Cutting tools
Oil impregnated bushings, filters

Fusion / Welding
Solder and brazing pastes
Welding and thermal spray

Other
Chemical
Agricultural
Food and pharmaceuticals

I Introduction

Casting, Forging, Machining, P/M, etc:

Which method to choose?
Quality, Quantity, Tolerance,
Geometry, Material, Environment,
Labor quantity, Skill level, Equipment,
Etc

I Introduction

LOWEST

COST!

I Introduction (cont.)

POWDER METALLURGY (P/M):

Full-scale Industrialization in past 50 years

>$1.8 Billion per year in North America

P/M Processing has Shown Continuous Annual

Growth for the Past 50 Years by
1) Replacing Existing Technologies
2) "DFM: Designed for Manufacturability"
Keep in mind that powder cost more than equivalent
cast or wrought material

II General Summary of The Science of P/M

P/M consists of three fundamental steps:

a) Powder Production
b) Powder Consolidation
c) Sintering

II General Summary of The Science of P/M

a) Powder Production
Atomization
o Electrolytic, precipitation
o Mechanical
o Chemical, reduction

II General Summary of The Science of P/M

a) Powder production by Atomization:

Disintegration of liquid stream by a second fluid

Gas Atomization
Spherical powder particles
Good "flowability"

Water Atomization:
Irregular powder particles
Good compactability

Atomization Schematics
Water Atomization

Water

Induction Coil

Water

Gas Atomization

Gas Atomized
Silver Alloy

Water
Atomized
Copper Alloy

II General Summary of The Science of P/M

b) Consolidation:
Impart shape to net or near net to powder mass
Net Shape:

Die Compaction
MIM (Metal Injection Molding)
Near Net Shape:

CIP (Cold Isostatic Pressing)

Hot Pressing
Extrusion
Rolling

II General Summary of The Science of P/M

c) Sintering:
Heat treatment to promote metallurgical integrity

Metallurgical Bonding
Densification (shrinkage)
Pore Elimination

III P/M Manufacturing Techniques

Net Shape Processing:

Direct process to final shape
Eliminate manufacturing operations
"Chipless" manufacturing,
low waste/scrap

III P/M Manufacturing Techniques Net Shape Processing

Die Compaction
Use water atomized powder (irregular shape)
Rigid tooling: tool steel, WC/Co
Pressures up to 60 tons/square inch
Production > 10,000 parts
High tolerance, 0.001 "/" possible
High productivity
Controlled porosity, density (85% to 90%)

Axis-symmetric
No undercuts
No off-axis attributes
L/D <5

III P/M Manufacturing Techniques

Net Shape Processing

MIM (Metal Injection Molding)

Plastic Injection Molding + Powder Metallurgy (P/M)

Complex Shapes
High density metal parts (> 95%)
Economy of Scale (high productivity)
Good tolerance, .003 "/" possible, .005-.008 "/" typ.

Competes with investment casting

and discrete machining

IV

Applications, General Case Studies:

Connecting Rod

IV

Applications, General Case Studies:

Connecting Rod

P/M Press-Sinter-Forge
vs. Power Forge
Better

material utilization
Fewer tool sets
Reduction of secondary machining operations
Large end bearing bore and mating flats
Eliminate balancing

IV

Applications, General Case Studies:

Orthodontia Brackets

IV

Applications, General Case Studies:

Orthodontia Brackets
MIM vs. Discrete machining and Investment casting:

Elimination of all machining operations

Better material utilization (no chips, sprues, etc)
Able to produce smaller parts than investment cast
Able to produce more complex geometries than machining
Massive reduction in labor
Complete payback in about 2 years

IV

Applications, General Case Studies

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IV

Applications, General Case Studies:

Wedding Band Blanks

IV

Applications, General Case Studies:

Wedding Band Blanks

P/M rings vs. Conventional methods

(stamp from sheet, cut from tube
Far Better material utilization (sheet scrap, saw kerf waste)

Lower cost material (wrt added value)

Massive reduction in labor

Improved material properties, better machinability

Applications, General Case Studies: Jewelry Applications

MIM Applications for Jewelry Items:

Reduction in Labor
Reduction in Defect Rate
Reduction in Precious Metal Content

Soluble Core MIM

Sinter-bonded MIM for hollow jewelry

P/M is so easy even a child can understand it.