{i0v-ak^-nbu}powde
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Powder MetalPowder Metal
ProcessingProcessing
ManufacturingManufacturing
ProcessesProcesses
By:By:
Dr.Behzad HeidarshenasDr.Behzad Heidarshenas
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OutlineOutline
IntroductionIntroduction
Powder ManufacturingPowder Manufacturing
Powder Metallurgy ProcessPowder Metallurgy Process
SinteringSintering
Other Powder Metal ProcessesOther Powder Metal Processes
Powder Metal ProductsPowder Metal Products
Powder Metallurgy DesignPowder Metallurgy Design
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Powder MetallurgyPowder Metallurgy
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Powder MetallurgyPowder Metallurgy
MetalMetal
Powder Powder
Metal ProductMetal Product
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Exa!les of PowderExa!les of Powder
Metal ProductsMetal Products"ears"ears
#as#as
#ran$s#ran$s
BearingsBearings
%oller &earing cages%oller &earing cages
HousingsHousings
'ight &ul& filaents'ight &ul& filaents
S!rin$ler echanissS!rin$ler echaniss
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Powder Metal MaterialsPowder Metal Materials
EleentalEleental
( !ure etal) ost coonly ( !ure etal) ost coonly
iron) aluinu or co!!er iron) aluinu or co!!er
PrealloyedPrealloyed
(n alloy of the re*uired (n alloy of the re*uired
co!osition) ost coonlyco!osition) ost coonly
co!!er alloys) stainless steelco!!er alloys) stainless steel
or high+s!eed steelor high+s!eed steel
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Powder ManufacturingPowder Manufacturing
#on,ersion of olten etal to#on,ersion of olten etal to
!owder !owder
(toization (toization
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Powder ManufacturingPowder Manufacturing
Other ethods of !roducingOther ethods of !roducing
!owder:!owder:
+ #heical reduction of#heical reduction of!articulate co!ounds!articulate co!ounds
+ Electrolytic de!ositionElectrolytic de!osition
+ Pul,erization or grinding ofPul,erization or grinding of&rittle aterials&rittle aterials
+ -heral deco!osition-heral deco!osition
+ Preci!itation fro solutionsPreci!itation fro solutions+ #ondensation of etal ,a!ors#ondensation of etal ,a!ors
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Particle Sha!eParticle Sha!e
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Particle SizeParticle Size
-he !rocess of se!arating !articles-he !rocess of se!arating !articles
&y size is called classification&y size is called classification
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Particle SizeParticle Size
Microgra!h of screened !owder !articles) showing
that !articles ay &e longer than the esh is wide
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Particle SizeParticle Size
,oid
saller) ore nuerous ,oids
,oids filled &y saller !articles)
sall ,oids reain
Mixing !articles of different sizes allows decreased
!orosity and a higher !ac$ing ratio
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Powder MetallurgyPowder Metallurgy
ProcessProcess
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Blending and MixingBlending and Mixing
BlendingBlending
#o&ining !owders of the sae aterial#o&ining !owders of the sae aterial
&ut !ossi&ly different !article sizes&ut !ossi&ly different !article sizes
MixingMixing
#o&ining !owders of different aterials#o&ining !owders of different aterials
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#o!action#o!action
High !ressure is a!!lied to s*ueezeHigh !ressure is a!!lied to s*ueeze
the !owder into the desired sha!ethe !owder into the desired sha!e
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Exa!le of a PowderExa!le of a Powder
PressPress
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Other Powder MetalOther Powder Metal
ProcessesProcesses#old Isostatic Pressing#old Isostatic Pressing
Hot Isostatic PressingHot Isostatic Pressing
Inection MoldingInection Molding
Powder %ollingPowder %olling
Powder ExtrusionPowder Extrusion
Plasa S!rayingPlasa S!raying
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Isostatic PressingIsostatic Pressing
/ses !ressurized fluid to co!ress the/ses !ressurized fluid to co!ress the!owder e*ually in all directions!owder e*ually in all directions
#old Isostatic Pressing#old Isostatic Pressing
#o!action !erfored at roo#o!action !erfored at roote!eraturete!erature
Hot Isostatic PressingHot Isostatic Pressing
Perfored at high te!eratures andPerfored at high te!eratures and
!ressures!ressures
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Exa!le of an IsostaticExa!le of an Isostatic
PressPress
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Inection MoldingInection Molding
-he !owder is ixed with a &inder-he !owder is ixed with a &inder
and olded) and the &inder isand olded) and the &inder is
reo,ed &efore sinteringreo,ed &efore sintering
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Powder %ollingPowder %olling
Powder is co!ressed in a rolling illPowder is co!ressed in a rolling ill
to for a stri!to for a stri!
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Powder ExtrusionPowder Extrusion
-he !owder can &e extruded within a-he !owder can &e extruded within a
container or after &eing fored intocontainer or after &eing fored into
&illets&illets
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Plasa S!rayingPlasa S!raying
/ses a !lasa arc to !ro!el olten/ses a !lasa arc to !ro!el olten
dro!lets at a surface at a highdro!lets at a surface at a high
,elocity) foring a high+density,elocity) foring a high+densitystructurestructure
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Plasa S!rayingPlasa S!raying
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SinteringSintering
Heats the !owder &elow the eltingHeats the !owder &elow the elting
!oint to allow solid+state diffusion!oint to allow solid+state diffusion
and &ond the !articles together and &ond the !articles together
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SinteringSintering
Diagra of !articles in sintering) showing the
!ossi&le o,eents of atos
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SinteringSintering
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SinteringSintering
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Sintering ProductionSintering Production
'ines'ines
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Exa!les of SinteringExa!les of Sintering
Production 'inesProduction 'ines
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SinteringSintering
Strength of sintered structures as related to density)
showing that the strength is higher when the density
is higher 0less residual !orosity1
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Powder Metal ProductsPowder Metal Products
2.2. Porous or !erea&lePorous or !erea&le!roducts!roducts
3.3. Products of co!lex sha!esProducts of co!lex sha!es4.4. Products ade of aterialsProducts ade of aterials
that are difficult to achine orthat are difficult to achine orha,e high elting !ointsha,e high elting !oints
5.5. Products which re*uire theProducts which re*uire theco&ined !ro!erties ofco&ined !ro!erties ofulti!le aterialsulti!le aterials
6.6. Products in which !owderProducts in which !owderetallurgy !roduces su!erioretallurgy !roduces su!erior!ro!erties!ro!erties
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Powder MetallurgyPowder Metallurgy
DesignDesign2.2. -he sha!e ust !erit reo,al-he sha!e ust !erit reo,al
fro the diefro the die
3.3. -he sha!e should not ha,e thin-he sha!e should not ha,e thinwalls or shar! cornerswalls or shar! corners
4.4. -he sha!e should !erit the-he sha!e should !erit the
construction of strong toolingconstruction of strong tooling
5.5. -he sha!e of the !art should &e-he sha!e of the !art should &e
within the thic$ness range forwithin the thic$ness range for
which the !owder can &e !ro!erlywhich the !owder can &e !ro!erly
co!actedco!acted
6.6. -he !art should ha,e as few-he !art should ha,e as few
changes in section thic$ness aschanges in section thic$ness as
!ossi&le!ossi&le
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Powder MetallurgyPowder Metallurgy
DesignDesign7.7. Parts can &e designed to ta$eParts can &e designed to ta$e
ad,antage of the ca!a&ilities ofad,antage of the ca!a&ilities of
the !owder etallurgy !rocessthe !owder etallurgy !rocess8.8. -he design should &e consistent-he design should &e consistent
with a,aila&le e*ui!entwith a,aila&le e*ui!ent
9.9. #onsideration should &e gi,en for#onsideration should &e gi,en for
!roduct tolerances!roduct tolerances.. Design should consider theDesign should consider the
diensional changes that occurdiensional changes that occur
after !ressing) such as shrin$ageafter !ressing) such as shrin$age
during sinteringduring sintering
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Powder MetallurgyPowder Metallurgy
DesignDesign
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Powder MetallurgyPowder Metallurgy
DesignDesign
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Powder MetallurgyPowder Metallurgy
(d,antages (d,antages2.2. Eliination;reduction ofEliination;reduction of
achiningachining
3.3. High !roduction ratesHigh !roduction rates
4.4. #o!lex sha!es can &e#o!lex sha!es can &e
!roduced!roduced
5.5. <ide co!osition ,ariations<ide co!osition ,ariationsare !ossi&leare !ossi&le
6.6. <ide !ro!erty ,ariations are<ide !ro!erty ,ariations are
!ossi&le!ossi&le7.7. Scra! is eliinated orScra! is eliinated or
reducedreduced
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Powder MetallurgyPowder Metallurgy
Disad,antagesDisad,antages2.2. Inferior strength !ro!ertiesInferior strength !ro!erties
3.3. %elati,ely high die cost%elati,ely high die cost
4.4. High aterial costHigh aterial cost
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SuarySuary
Powder etallurgy can createPowder etallurgy can create
!arts that would otherwise &e!arts that would otherwise &e
difficult to for) including thosedifficult to for) including thosewith co!lex sha!es orwith co!lex sha!es or
!orosity!orosity
Sintering &onds !articlesSintering &onds !articles
together &y allowing atos totogether &y allowing atos to
o,e) foring nec$s and graino,e) foring nec$s and grain
&oundaries &etween the&oundaries &etween the
!articles!articles
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