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  • Powder Metallurgy (P/M) : Method

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    Gautam Sharma
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    Powder Metallurgy (P/M) is a manufacturing process that involves mixing metal powders, compacting them under pressure, and then sintering the compact to produce parts. Some key advantages of P/M over casting include producing net-shape small steel parts with less waste, offering unusual alloy combinations, and using less energy. P/M is commonly used to make gears, cutting tools, porous metals like filters or bearings, connecting rods, transmission gears, and turbine blade-disks.

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    Powder Metallurgy (P/M) is a manufacturing process that involves mixing metal powders, compacting them under pressure, and then sintering the compact to produce parts. Some key advantages of P/M over casting include producing net-shape small steel parts with less waste, offering unusual alloy combinations, and using less energy. P/M is commonly used to make gears, cutting tools, porous metals like filters or bearings, connecting rods, transmission gears, and turbine blade-disks.

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    20 views9 pages

    Powder Metallurgy (P/M) : Method

    Uploaded by

    Gautam Sharma
    Powder Metallurgy (P/M) is a manufacturing process that involves mixing metal powders, compacting them under pressure, and then sintering the compact to produce parts. Some key advantages of P/M over casting include producing net-shape small steel parts with less waste, offering unusual alloy combinations, and using less energy. P/M is commonly used to make gears, cutting tools, porous metals like filters or bearings, connecting rods, transmission gears, and turbine blade-disks.

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    of 9

    Powder Metallurgy (P/M)

    Method:
    • Make fine metal powders and sort
    • Mix powders to get “alloy”
    • Iron alloys most common, also Bronze
    • Compaction
    • Powder is pressed into a “green compact”
    • 20,000-100,000psi pressure
    • Still very porous, ~70% density
    • May be done cold or warm (higher density)
    • Sintering
    • Controlled atmosphere: no oxygen
    • Heat to .75*Tmelt
    • Particles bind together P/M net-shape gears are common, save machining time
    • Part shrinks in size
    • Density increases, up to 95%
    • Strength ~=~ Density

    P/M (vs. Casting):


    • Mass produce small steel parts, net-shape
    • Less waste
    • Unusual “alloys”
    • Range of densities, porosity (adv or disadv)
    • Less energy use
    • But: Smaller parts and less complexity (2.5D) oee.nrcan.gc.ca
    Powder Metallurgy

    Slightly porous appearance is common

    Range of particle sizes

    www.buau.com.au
    www.parmaco.com
    Cermet cutting inserts for lathe

    Powder Metallurgy:
    Cermet cutting tools
    (Ceramic-Metal composite)

    www.kyocera-yashica.com.br

    Cermet-tipped saw blade for long life


    Microstructure: ceramic particles in metal matrix

    www.moldmakingtechnology.com

    www.toolbarn.com
    Metal filters

    Powder Metallurgy:
    Porous Metals

    Oil-impregnated Porous Bronze Bearings nic.sav.sk

    www.ondrives.com

    www.hd-bearing.com
    Powder Metallurgy: Connecting Rods

    www.dps-performance.com

    Forged on left; P/M on right


    Powdered Metal Transmission Gear

    www.chipm.com

    • Warm compaction method with 1650-ton press


    • Teeth are molded net shape: No machining
    • UTS = 155,000 psi
    • 30% cost savings over the original forged part
    Powdered Metal Turbine blade-disk (“blisk”): 1 piece!

    www.ml.afrl.af.mil
    Conventional Forging vs. Forging of Powdered Metal blank (2nd op)

    DeGarmo
    References

    DeGarmo: E.P. DeGarmo et al, Materials and Processes in


    Manufacturing, Wiley, 2003.

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