Metal Powder Processing

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Powder Compaction and Sintering

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Powder-Metallurgy gy
(a) (c)

(b)

(a) Examples of typical parts made by powderpowder metallurgy processes. (b) Upper trip lever for a commercial irrigation sprinkler, made by P/M. This part is made of unleaded brass alloy; it replaces a die-cast part, with a 60% savings. Source: Reproduced with permission from Success Stories on P/M Parts, 1998. Metal Powder Industries Federation, Princeton, New Jersey, 1998. (c) Main-bearing powder metal caps for 3.8 and 3.1 liter General Motors automotive engines. engines Source: Courtesy of Zenith Sintered Products, Inc., Milwaukee, Wisconsin.
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 3

Typical Applications for Metal Powders

Application Abrasives Aerospace Automotive Electrical/electronic Heat treating Joining Lubrication Magnetic Manufacturing Medical/dental Metallurgical Nuclear Office equipment Source: R. M. German. Metals Fe, Sn, Zn Al, Be, Nb Cu, Fe, W Ag, Au, Mo Mo, Pt, W Cu, Fe, Sn , Fe, , Zn Cu, Co, Fe, Ni Cu, Mn, W Ag, Au, W Al Ce, Al, Ce Si Be, Ni, W Al, Fe, Ti Uses Cleaning, abrasive wheels Jet engines, heat shields Valve inserts, bushings, gears Contacts, diode heat sinks Furnace elements, thermocouples Solders, electrodes Greases, , abradable seals Relays, magnets Dies, tools, bearings Implants, amalgams Metal recovery recovery, alloying Shielding, filters, reflectors Electrostatic copiers, cams

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Making Powder-Metallurgy Powder Metallurgy Parts

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Powder Processing
Cold compaction p and sintering g
Pressing Rolling g Extrusion Injection molding Isostatic pressing

Hot Isostatic Pressing

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Powder Pressing g
Punch

Die

Part

Punch

Dual action press

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 7

Compaction p
(a) Compaction of metal powder to form a bushing. The pressed powder p p part is called g green compact. (b) Typical tool and die set for compacting a spur gear. Source: Metal Powder Industries Federation.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Mechanical Press
A 7.3 MN (825 ton) mechanical press for compacting metal powder. Source: Courtesy of Cincinnati Incorporated.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

Powder Rolling

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Powder Extrusion

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Cold Isostatic Pressing

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Hot Isostatic Pressing g

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Hot Isostatic Pressing

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Particle Shapes p in Metal Powders

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Powder Particles
(a) (b)

(a) Scanning-electron-microscopy Scanning electron microscopy photograph of iron-powder iron powder particles made by atomization. atomization (b) Nickel-based superalloy (Udimet 700) powder particles made by the rotating electrode process; see Fig. 17.5b. Source: Courtesy of P. G. Nash, Illinois Institute of Technology, Chicago.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Atomization and Mechanical Comminution

Methods M th d of f metal-powder t l d production by atomization; (a) melt atomization; (b) atomization with a rotating consumable electrode.

Methods of mechanical comminution, to obtain fine particles: (a) roll crushing, (b) ball mill, and (c) hammer milling.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Compacting Pressures for Various Metal Powders

Metal Aluminum Brass Bronze Iron Tantalum Tungsten Other materials Aluminum oxide Carbon Cemented carbides Ferrites Pressure P (MPa) 70275 400700 200275 350800 70140 70 140 70140 110140 140165 140400 110165

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Sintering g
Schematic illustration of two mechanisms for sintering metal powders: (a) solid-state material transport; (b) liquid-phase material transport. R = particle radius, r = neck radius, and = neck profile radius.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Sintering g

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Sintering Temperature and Time for Various Metals

Material Copper, brass, and bronze Iron and iron iron-graphite graphite Nickel Stainless steels Alnico alloys y (for permanent magnets) Ferrites Tungsten carbide M l bd Molybdenum Tungsten Tantalum Temperature T t ( C) 760900 1000 1150 10001150 10001150 11001290 12001300 12001500 14301500 2050 2350 2400 Time Ti (Min) 1045 8 45 845 3045 3060 120150 10600 2030 120 480 480

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Sintering Problems
Voids Incomplete fusion

vs.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Density Effects
(a) Density of copper- and iron-powder compacts as a function of compacting pressure. Density greatly influences the mechanical and physical properties of P/M parts. Source: F. V. Lenel, Powder Metallurgy: Principles and Applications. Princeton, Princeton NJ; Metal Powder Industries Federation Federation, 1980. 1980 (b) Effects of density on tensile strength, elongation, and electrical conductivity of copper powder. IACS means International Annealed Copper Standard for electrical conductivity.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Density Variations in Dies

Density variation in compacting metal powders in various dies: (a) and (c) single-action press; (b) and (d) d bl double-action ti press. N Note t in i (d) th the greater t uniformity if it of fd density, it f from pressing i with ith two t punches h with ith separate movements, compared with (c). (e) Pressure contours in compacted copper powder in a singleaction press. Source: P. Duwez and L. Zwell.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Capabilities Available from P/M Operations

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Mechanical Property Comparison for Ti-6Al-4V Ti 6Al 4V

Yield Ultimate Density strength strength Elongation Reduction of Process(*) (%) (MPa) (MPa) (%) area (%) Cast 100 840 930 7 15 Cast and forged 100 875 965 14 40 Blended elemental (P+S) 98 786 875 8 14 Blended elemental (HIP) > 99 805 875 9 17 Prealloyed (HIP) 100 880 975 14 26 (*) P+S = pressed and sintered, HIP = hot isostatically pressed. Source: R.M. German.

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Rules for P/M Parts

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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Forged and P/M Titanium Parts and Potential Cost Saving

Weight (kg) Part F 14 Fuselage brace F-14 F-18 Engine mount support F-18 Arrestor hook support fitting F-14 Nacelle frame Forged billet 28 2.8 7.7 79.4 143 P/M 11 1.1 2.5 25.0 82 Final part 08 0.8 0.5 12.9 24.2 Potential cost saving (%) 50 20 25 50

ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009

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