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INDEX
1. Introduction
2. Powder Metallurgy Process :
a. Powder Manufacture.
b. Blending ,Mixing.
c. Compaction.
d. Sintering.
e. Secondary Operations.
f. Impregnation and Infiltration .
3. Advantages ,Disadvantages , conclusions,
Applications.
4. Manufacture of some important P/M components
History of Applications
3000 B.C. Egyptians made tools with powder
metallurgy
1900s tungsten filament for light bulb
1930s carbide tool materials
1960s automobile parts
1980s aircraft engine turbine parts
Currently, North American P/M sales are over
$5billion annually
Indian History
The Delhi Iron Pillar was
produced in the fourth century
AD by a technique that would
appear to be very similar to
current powder forging, in
which sponge iron pieces
obtained by direct reduction of
selected iron ore pieces were
hot forged successively into a
long cylindrical object.
Why Powder Metallurgy is Important?
Compaction
Sintering
Finished Product
The Powder Metallurgy Process
Five basic steps involve in powder
metallurgy process :
1. Powder production
2. Blending and mixing
3. Compacting
4. Sintering and impregnation
5. Testing and inspection
Engineering Powders
Microscopic Cold
Density
method mounting
Sedimentation
Flow rate
method
Compacting
properties
Several of the possible (ideal) particle
shapes in powder metallurgy
Production of Metallic Powders
Powder Production Processes
Graining
Atomization
Mechanical Processes
Pre-sintering
Mechanism in sintering
Quite complex depends on process
parameters.
Sintering time, pressure and atmosphere.
Mechanism involved are
a. Diffusion
b. Densification
c. Recrystallization
d. Grain growth
Sinter involves mass transport (diffusion) to
create necks and transform into grain
boundaries. Powder size small, higher surface
area and greater driving force.
Sintering Process
Main operation.
Heating material below melting point to bond
particles and increase strength.
Uses a sintering atmosphere and a sintering
furnace ( Continuous Belt Furnace).
The atmosphere transfers heat to the
compacted powder, adjusts impurity levels and
remove lubricants.
Atmosphere can be pure hydrogen, nitrogen
or ammonia.
Continuous Belt Furnace Bonding of particles in Sintering
Sintering on Particles
The particles will stretch and densification
will form in places of rapid shrinking.
Furnace provides time and temp. control.
Continuous Furnace
Typical sintering cycle
Sinteringsolid state/phase sinterin
Heat treatment to bond the metallic particles,
thereby increasing strength and hardness.
Usually carried out at between 70% and 90%
of the metal's melting point (absolute scale).
Primary driving force for sintering is reduction
of surface energy.
Part shrinkage occurs during sintering due to
pore size reduction.
Sintering on a microscopic scale: (1) particle bonding is initiated at
contact points; (2) contact points grow into "necks"; (3) the pores
between particles are reduced in size; and (4) grain boundaries
develop between particles in place of the necked regions
Sintering time and temperature
on density and strength
Importance
gear-parts
industrial-machinery pulley-parts
self-lubrication-bearing other
Powdered Metal Turbine blade-disk
Manufacture of some important P/M
components
1.Mixing
2.Cold compaction
3.Sintering
Reducing atmosphere
400-450 C for 1-2 hours to remove part of
graphite
800 C for 5 minutes for diffusion of molten
Sn into Cu
4. Repressing or Machining
Pore size - large sizing
- small - machining
5. Impregnation
Characteristics
Sufficient porosity
Inter connected porosity
Sufficient strength
Good dimensional accuracy
Effect of porosity
Applications
Powder manufacture
Milling
To facilitate pressing
Avoid defects and cracks
Cold pressing and sintering
400 C removal of lubricant
900-1150 C sufficient strength
1350-1550 C hydrogen atmosphere
Machining
Tungsten Dried
Carbon Re-reduced
Carburized screened
CCTT
Characteristics
Cold and hot hardness
Compressive strength
Modulus of elasticity
Abrasion resistance
Cutting ability
Production of refractory metals
Refractory metals
W, Mo, Nb, Ta, Pt
Powder production
Cold compaction
Presintering
Final sintering
by passing electric current
Applications
high temp furnace, hook in thermoionic
valve,
Diamond Impregnated Tools
Composition
Diamond dust
Powder of bonding material
Production process
Cold compaction
Sintering
1000 C in vacuum or reducing atmosphere
Characteristics
Close dimensional tolerances
Cutting efficiency
Surface finish
Long tool life
Applications
Cutting, Drilling, Shaping, Sawing, Finishing
For wire drawing
Electrical contact materials
Properties required
High electrical and thermal conductivity
High melting point
High resistance to wear, abrasion and
sparking
Low contact resistance
Low vapour pressure
Manufacturing processes
Conventional pressing and sintering
followed by further cold or hot working
Pressing, sintering and infiltration
Examples
Simple refractory metals such as W and Mo,
W-Cu, W-Ag, WC-Ag, Ni-Ag, Ag-graphite,
Cu-graphite
Powder Metallurgy Casting
1. It is production of metal and non metal powders and 1. It is production of components by pouring molten metals into
manufacture of components by using this powder. the moulds.
6. Complex shape parts cannot be manufactured easily. 6. Complex shapes can be obtained easily.
6. Examples 7. Examples
Self lubricating bearings, CCTT, Crank shaft, metal dies ,
Diamond impregnated tools, Etc.
Production of refractory metals
Cermet cutting inserts for lathe
Thank you !