MECH 421 /6511 Homework 1 (Chap 6 P/M)

Question 1: It is possible to infiltrate P/M parts with various resins, as well as with metals. What possible benefits would result from infiltration? Give some examples.

Question 2: Should green compacts be brought up to the sintering temperature slowly or rapidly? Explain.

Question 3: Explain the effects of using fine vs. coarse powders in making P/M parts.

Question 4: Describe the relative advantages and limitations of cold and hot isostatic pressing, respectively. Question 5: Why do mechanical and physical properties depend on the density of P/M parts? Explain. Question 6: Why is there density variations in compacted metal powders? How is it reduced?

Problem 1 A gear is to be manufactured from iron powder. It is desired that it have a final density that is 90% of that of cast iron, and it is known that the shrinkage in sintering will be approximately 5%. For a gear 2.5-in. in diameter and with a 0.75-in. hub, what is the required press force? Problem 2

The axisymmetric parts shown in the accompanying figure are to be produced through P/M. Describe the design changes that you would recommend.

Problem 3 The part shown in Figure P16.13 is to be pressed of iron powders using a compaction pressure of 75,000 lb/in2. Dimensions are inches. Determine (a) the most appropriate pressing direction, (b) the required press tonnage to perform this operation, and (c) the final weight of the part if the porosity is 10%. Assume shrinkage during sintering can be neglected.

Problem 4: For each of the four part drawings in Figure P16.14, indicate which PM class the parts belong to, whether the part must be pressed from one or two directions, and how many levels of press control will be required? Dimensions are mm.