Powder Metallurgy

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
• 1900’s tungsten filament for light bulb
• 1930’s carbide tool materials
• 1960’s automobile parts
• 1980’s 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?

• PM parts can be mass produced to net

shape or near net shape, eliminating or
reducing the need for subsequent machining.
• PM parts can be made with a specified level
of porosity, to produce porous metal parts.
• Examples: filters, oil-impregnated bearings
and gears.
• Certain metals that are difficult to fabricate by
other methods can be shaped by powder
metallurgy.
• Example: Tungsten filaments for incandescent
lamp bulbs.
• PM compares favorably to most casting
processes in dimensional control.
Basics of Powder Metallurgy

• The Characterization of Engineering Powders.

• Production of Metallic Powders.
• Conventional Pressing and Sintering.
• Alternative Pressing and Sintering Techniques.
• Design Considerations in Powder Metallurgy.
 Metal Powder Additives

Mixing & Blending

Compaction

Sintering

optional secondary optional Finishing

manufacturing operations

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

A powder can be defined as a finely divided

particulate solid.
• Engineering powders include metals, alloys
and ceramics.
• Geometric features of engineering powders:
• Particle size (mesh size) and distribution.
• Particle shape and internal structure.
• Surface area.
 Characterization

Chemical Shape, Size & Particle porosity Other

Composition distribution & microstructure properties

Sieve Hot Specific

method mounting surface

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

Mechanical Physical Chemical Electrochemical

Machining Condensation Reduction

Crushing Thermal Intergranular

Decomposition Corrosion
Milling
Precipitation
Shotting

Graining

Atomization
Mechanical Processes

Machining: relatively coarse powders are

obtained by this method
Crushing: this method is very suitable for brittle
materials
Milling: can be obtained powders of required
grade and fineness
Ball Mill Mechanical
Several atomization methods

a and b – gas Atomization c – water atomization d - centrifugal atomization

Atomization

Water Atomization Process:

Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.
 Vertical Gas Atomizer:
Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.
Centrifugal Atomization by the Rotating Electrode
Process:
Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.
Chemical Processes
Chemical methods constitute the final
manufacturing group. Included are the
production of metal powders by the reduction of
metallic oxides, precipitation from solution
(hydrometallurgy), and thermal decomposition
(carbonyl)
Electrolytic

Electrolytic Cell Operation for Deposition of Powder-

Schematic:
Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.
Physical Processes

Condensation: metal vapours are condensed

and suitable for volatile metals
Thermal Decomposition: highly suitable for
manufacture of Fe and Ni powders
Range of particle sizes
Blending of Powders

• For successful results in compaction and

sintering, the starting powders must be
homogenized.
• Blending - powders of the same chemistry but
possibly different particle sizes are intermingled.
• Different particle sizes are often blended to
reduce porosity.
Mixing of Powders
• Mixing - powders of different chemistries are
combined.
• PM technology allows mixing various metals
into alloys that would be difficult or impossible to
produce by other means.
• Other ingredients.
• Lubricants – reduce friction between particles
and die walls , Lubricant affects both sintered
and un-sintered strengths.
• Binders – achieve adequate strength for un-
sintered part.
• De-flocculants – avoid aggolomeration.
•The purpose of mixing is to provide a
homogeneous mixture and to incorporate the
lubricant.
.
Compacting
• Application of high pressure to the powders to
form them into the required shape.
• The conventional compaction method is
pressing, in which opposing punches squeeze
the powders contained in a die.
• The work part after pressing is called a green
compact, the word green meaning not yet fully
processed.
Pressing in PM: (1) filling die cavity with powder
by automatic feeder; (2) initial and (3) final
positions of upper and lower punches during
pressing, and(4) ejection of part
Effect of compaction pressure on green density
Consolidation of powdered material can also be
done by:
• Isostatic pressing
• High energy rate forming
• Powder rolling or Roll compacting
• Powder extrusion
• Vibratory compacting
Isostatic Pressing

• Here pressure is applied simultaneously and

equally in all direction through gases or
hydraulic medium to obtain uniform density
and strength.
• Produces powder metal parts to near full
density and shapes of varying complexity.
• Uses lower pressures to densify a powder
by atomic movement.
Hot Isostatic Pressure System
Importance
• It reduces voids , increases the density.
• It produces adhesion It plastically deforms the
powder and allows recrystallization during
sintering.
Forming
• Final Shape and Mechanical properties are
determined.
• Die Compacting
• Cold-welding of particles

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
Sintering–solid 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

• Increase in density and strength.

• Disappearance of particle boundaries.
• Other mechanism is plastic deformation.
• Liquid phase sintering (alloys).
 Sintering Problems
• Voids
• Incomplete fusion
Secondary Operations
Secondary operations are performed to increase
density, improve accuracy, or accomplish
additional shaping of the sintered part
• Repressing - pressing the sintered part in a
closed die to increase density and improve
properties.
• Sizing - pressing a sintered part to improve
dimensional accuracy.
• Coining – press working operation on a
sintered part to press details into its surface.
Machining - creates geometric features that
cannot be achieved by pressing, such as
threads, side holes, and other details
• Compaction and sintering together
• Hot Isostatic pressing
• Spark sintering
 Impregnation and Infiltration
• Porosity is a unique and inherent characteristic
of PM technology.
• It can be exploited to create special products
by filling the available pore space with oils,
polymers, or metals.
Two categories:
1. Impregnation
The term used when oil or other fluid is
permeated into the pores of a sintered PM part.
2. Infiltration
An operation in which the pores of the PM part
are filled with a molten metal.
Powder/Metal Injection Molding (PIM/MIM)

• Ceramic particles are mixed with a thermoplastic

polymer/metal, then heated and injected into a mold
cavity.
• The polymer acts as a carrier and provides flow
characteristics for molding.
• Upon cooling which hardens the polymer, the mold is
opened and the part is removed.
• Because temperatures needed to plasticize the carrier
are much lower than those required for sintering the
ceramic, the piece is green after molding.
• The plastic binder is removed and the remaining
ceramic part is sintered.
Advantages
1.Ability to create complex shapes
2.High strength properties
3.Low material waste
4.Good microstructure control
5.Uses more than 97% of the starting raw
material in the finished part
6.Eliminates or minimizes machining
7.Maintains close dimensional tolerances
8.Wide variety of alloys
9.Mass production
10.Cost and energy efficient
 Disadvantages
1. Cost of powder production.
2. Limit on complexity of shapes.
3. Size will change during sintering.
4. can be predicted.
5. Potential workforce health problems due to
atmospheric contamination.
6. Creation of residual pores.
7. High tooling costs.
8. Variations in density throughout part may be
a problem,especially for complex geometries.
Conclusions
• P/M is a proven technology dating back
centuries.
• By utilizing 97% original material, cost and
energy are minimized
• Properties and dimensions are easily
controlled.
• Wide variety of P/M applications which are still
increasing
Applications
• Only way of forming superalloys, tungsten
carbide.
• Typical U.S. 5- or 6-passenger car contains
more than 35 lbs of P/M parts.
• Commercial aircraft engines contain
1,500-4,400 lbs of P/M parts.
• Gears, cams.
• Household goods.
automobile-motorcycle oil-pump

gear-parts

industrial-machinery pulley-parts

self-lubrication-bearing other
Powdered Metal Turbine blade-disk
Manufacture of some important P/M
components

• Self lubricating bearings

• Cemented carbide tipped tools
• Diamond impregnated tools
• Production of refractory metals
• Electrical contact materials
Self lubricating Bearings
• Manufactured from either bronze , brass ,
iron or aluminium alloy powders with or
without graphite.
• Bronze bearings are widely used (Cu:Sn-
90:10).
• Some amount of free graphite is desirable
because it is a solid lubricant and takes care
under severe loading conditions.
The steps in the production of a
porous bronze bearing

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

• Difficultly accessible places

• Regular lubrication
• Applications where it is desirable that oil
should not come in contact and contaminate
the product
SLB with slightly porous appearance
Oil-impregnated Porous Bronze
Bearings
Cemented Carbides
• Important products of P/M.
• Find wide applications as cutting tools, wire
drawing and deep drawing dries .
• Manufactured from carbides of refractory
metals such as W, Mo ,Ti ,Ta or Nb.
• Extremely hard and retain their hardness upto
a very high temperature.
• However they are extremely brittle and are
likely to fail with slight shock loading.
The Steps In Manufacture Of
Cemented Carbides:

• 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

W & C powder Lubricant add

Carbide solid solution Pressing Presintring

Crushed & screened pressing

Ball mill Final sintering

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.

1. Controlled porosity can be obtained. 2. Control porosity cannot be

Obtained.

2. Close control over the dimension. 3. Dimensional accuracy is less.

4. Patterns are not required. 4. Patterns are required

4. Poor corrosion resistance due to porosity. 5. High corrosion resistance.

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 !