MM 357 Ceramics and Powder

Metallurgy
Powder Metallurgy:
Lecture 2

Powder Manufacturing

Sudhanshu Mallick
1
German, P 85
Mechanical Powder Fabrication
Techniques
Machining:
Coarse powders are produced during
machining of metals. The powders can be
further refined by grinding.

The rapid heating and cool down cycle
that the machining produced particles can
cause the particle surface to get oxidized.

It also results in the formation of various
phases (different from the original metal
these particles were machined from)
which may give them different properties
2
Mechanical Powder Fabrication
Techniques
Milling:
Milling is process of reducing particle size by mechanical
impaction using hard balls.

Useful for brittle materials. Ductile particles cold weld
and stick together

Optimal conditions:
Rotation speed fast enough to carry the balls to the top
of the jar. Too slow insufficient impact force, Too fast
Balls stick to the jar surface by centrifugal force
Ball diameter approx 30 times the powder size
Volume of balls approx half the jar volume
Volume of powder approx 25% of jar volume fills the
interstitials between the grinding balls.

Contamination from jar and milling balls is a concern

3
German, P 86
German, P 89
Mechanical Powder
Fabrication Techniques
Mechanical alloying:
Though not really a Powder
formation technique, Its being
discussed here because of
continuity.

Powders of different materials
are taken in appropriate
proportions and mixed in a
stirring mill with the aid of
milling balls.

The repeated impact, cold
welding and fracture produce
the desired composite powder

4
Gas Atomization - Horizontal
Typically used for low melting point metals
Gas emerging from the nozzle creates a siphon effect .
High velocity gas breaks up the metal into droplets
During flight the droplets loose heat, solidify and settle down
5
German, P 100
German, P 101
Gas Atomization - Vertical
Typically used for high melting
point metals
Closed inert gas filled chamber is
used to prevent oxidation.
High velocity gas breaks up the
metal into droplets
During flight the droplets loose
heat, solidify before touching the
chamber walls and settle down
Depending on the superheating,
gas flow rate, nozzle geometry,
particles of various shapes can be
formed

6
Water Atomization
High pressure jets are directed against stream of molten metals
causing disintegration and rapid solidification.
Synthetic oils or other non-reactive liquids can also be used
instead of water to achieve desired particle shape and
prevent oxidation
7
German, P 107
German, P 108
Centrifugal Atomization
Use centrifugal force to spray molten metal which solidifies into
a powder.
Better control over particle size
Typically done in inert atmosphere to prevent oxidation
Gives coarse particle sizes


8
German, P 111
German, P 113
Powder formation by Electrolysis
Used the conventional electrolysis principle (dissolution of Anode,
deposition at Cathode) to precipitate out powders

Metallic ions are generated by the dissolution of the Anode.
Transport of the ions through the electrolyte
Ions redeposit on the cathode
Cathode is washed and ground to produce powders
Depending on the conditions of the electrolytic cell (temp, voltage etc),
powders of different morphologies can be prepared
9
German, P 90
Powder manufacturing - Chemical
methods
Reduction / decomposition of a solid
Thermal decomposition (carbonyl)
Hydride De hydride
Reaction from a liquid
Precipitation from a liquid
Pechini process
Sol-gel method
Precipitation from a liquid
Precipitate from a super saturated solution
Large quantity of a soluble component is dissolved at a higher
temperature
At supersaturation, a large number of nuclei form suddenly
All nuclei grow at same rate uniform size distribution
Precipitation of mixed oxides is possible:
Fabrication of Nickel ferrite (magnetic) aqeous solution
of iron and nickel sulfate in solution at 80C, when pH is
increased to 11 with Ammonium hydroxide, a mixed
hydroxide precipitates washed and dried.
Precipitation from a liquid
Pechini method

Sol-Gel synthesis

Sol-Gel method
Metal alkoxide is formed by reaction of meals with alcohol
nROH + Me = (RO)nMe + (n/2) H2
Eg Al reacts with isopropanol at 80C in presence of HgCl2
catalyst
Alkoxides are commercially available.
Shape formation
Gelation
Calcination
High chemical homogeneity
Key variables:
Rate of Hydrolysis and condensation influence the
microstructure.
Type of alkoxide, Reaction temperature, pH, Amount of water
added (affects degree of polymerization)
15
Sol-Gel method

17
Rotary Calciner
18
Moulson, P 102