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MODULE 5A
LEARNING OBJECTIVES
Introduction
Advantages/Limitations
PM Products
PM Materials/Process Description
PM Steps
Powder manufacturing
Mixing/blending
Conventional pressing / compaction
Conventional sintering
Tape casting , isostatic pressing, powder extrusion , powder rolling ,
injection molding
Secondary operations in PM
Economic and design guide lines
Comparison with other manufacturing process
INTRODUCTION
Although the process has existed for more than 100 years, over the
past quarter century it has become widely recognized as a superior
way of producing high-quality parts for a variety of important
applications.
This success is due to the advantages the process offers over other
metal forming technologies such as forging and metal casting,
advantages in material utilization, shape complexity, near-net-shape
dimensional control, among others.
Metal
Powder
Metal Product
PM LIMITATIONS
Design Limitations
Gears
Cams
Cranks
Bearings
Housings
Sprinkler mechanisms
PM PRODUCTS
PM PRODUCTS
PM PRODUCTS
PM PRODUCTS
PM PRODUCTS
Powder Production
Blending or Mixing
Powder Consolidation
Sintering
Finishing Operation
FLOW CHART PM
POWDER PRODUCTION
POWDER PRODUCTION
Atomization
Electrolysis
Chemical.
However, atomization is widely used for powder production.
This has been for long the most widely used method for the
production of iron powder. Selected ore is crushed, mixed with
carbon, and passed through a continuous furnace where reaction
takes place leaving a cake of sponge iron which is then further
treated by crushing, separation of non-metallic material, and sieve to
produce powder.
ATOMIZATION
Air, nitrogen and argon are commonly used gases, and water is the
liquid most widely used
Contd
PARTICLE SHAPE
DUE USE OF GAS
CENTRIFUGAL ATOMIZATION
In one a cup of molten metal is rotated on a vertical axis at a speed sufficient to throw off
droplets of molten metal, or a stream of metal is allowed to fall on a rotating disc or cone;
In the other a bar of the metal is rotated at high speed and the free end is progressively
melted e.g. by an electron beam or plasma arc
POWDER CHARACTERISTICS
The further processing and the final results achieved in the sintered
part are influenced by the characteristics of the powder:
particle size,
size distribution,
particle shape,
structure
and surface condition.
PARTICLE SHAPE
PARTICLE SIZE/CLASSIFICATION
PARTICLE SIZE
Micrograph of screened powder particles, showing that particles may
be longer than the mesh is wide
PARTICLE SIZE
Mixing particles of different sizes allows decreased porosity and a
higher packing ratio
void
Contd
The ease and efficiency of packing the powder in the die depends to
a large extent on a wide particle size distribution so that the voids
created between large particles can be progressively filled with
those of smaller size.
Fine particle sizes tend to leave smaller pores which are easily
closed during sintering.
BLENDING OR MIXING
BLENDING OR MIXING
Lubricants may
characteristics.
be
mixed
to
improve
the
powders
flow
Blending
Combining powders of the same material but possibly different
particle sizes
Mixing
Combining powders of different materials
POWDER
CONSOLIDATION/COMPACTION
POWDER CONSOLIDATION/COMPACTION
COMPACTION SUMMARY
Application of high pressure to the powders to form them into the
required shape
The work part after pressing is called a green compact, the word
green meaning not yet fully processed
SINTERING
SINTERING
CONTD
In the cooling zone of the sintering furnace, the parts are cooled under
protective atmosphere in order to not oxidise in contact with air.
The cooling speed, especially in the range 850 - 500C, also affects the
mechanical properties, due to phase transformations in the material.
LIQUID-PHASE SINTERING
SINTERING FURNACE
Slip Casting
Cold Isostatic Pressing
Hot Isostatic Pressing
Powder Extrusion
Injection Molding
Powder Rolling
SLIP CASTING
ISOSTATIC PRESSING
CONTD.
WET BAG
In the wet bag method the mold is removed and refilled after each
pressure cycle.
This method is suitable for compaction of large and complicated
parts.
DRY BAG
The dry bag method is suitable for compaction of simpler and smaller
parts.
The work pressures, which are applied in the hot Isostatic pressing
method, are commonly b/w 100 MPa to 300 MPa.
The part shrinks and densifies, forming sound high strength structure.
POWDER EXTRUSION
Powders are placed in vacuum tight sheet can, heated and extruded
with container
POWDER ROLLING
Injection of the warm powder with molten binder into the mold by means of
the screw.
Removal of the part from the mold after cooling down of the mixture.
The powder is mixed with a binder and molded, and the binder is
removed before sintering
FINISHING OPERATIONS
Finishing operations include:
Machining
Heat Treatment
Calibration
Infiltration
Oil Impregnation
Joining
MACHINING
However there are features, such as re-entrant angles and cross holes,
that cannot be developed in the pressed component and must be
produced by machining, usually after final sintering.
HEAT TREATMENT
CALIBRATION
INFILTRATION
OIL IMPREGNATION
Metal filters
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Quite moderate pressures are normally required for sizing, since only
a slight plastic deformation is necessary.
PM PROCESS SUMMARY
Part must have vertical or near vertical sides, although steps are
allowed
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PM SUMMARY
ASSIGNMENT