Ch11 PDF

P/M Parts
(a)
(b)
FIGURE 11.1 (a) Examples of typical parts made by powder-metallurgy processes. (b) Upper trip lever for a
commercial irrigation sprinkler, made by P/M. Made of unleaded brass alloy, it replaces a die-cast part, at a 60%
cost savings. Source: Courtesy of Metal Powder Industries Federation.
Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Particle Shapes
Acicular (chemical
decomposition)
Irregular rodlike
(chemical decomposition,
mechanical comminution)
(a) One-dimensional
Spherical
(atomization,
carbonyl (Fe),
precipitation
from a liquid)
Flake (mechanical
comminution)
Dendritic
(electrolytic)
(b) Two-dimensional
Irregular
(atomization,
chemical
decomposition)
Rounded
(atomization,
chemical
decomposition)
Porous
(reduction
of oxides)
Angular
(mechanical
disintegration,
carbonyl (Ni ))
(c) Three-dimensional
FIGURE 11.2 Particle shapes and characteristics of metal powders and the processes by which they are produced.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Powder Production
Ladle
Molten metal
Tundish
Tundish
High-pressure
water manifold
Atomizing
gas spray
Atomization tank
Atomizing chamber
Metal particles
Water
atomization
Dewatering
(b)
(a)
Inert gas
Vacuum
Ladle
Rotating consumable
electrode
Molten metal
Tundish
Spindle
Liquid metal
Nonrotating
tungsten electrode
Metal particles
Collection port
Spinning disk
(c)
(d)
FIGURE 11.3 Methods of metal-powder production by atomization: (a) gas atomization; (b) water
atomization; (c) atomization with a rotating consumable electrode; and (d) centrifugal atomization
with a spinning disk or cup.
Kalpakjian Schmid
ISBN No. 0-13-227271-7
Particle Size Distribution

Cumulative weight finer (%)
20
Weight (%)
15
10
5
0
10
100
Particle size (m)
1000
(a)
100
75
50
25
0
10
100
Particle size (m)
1000
(b)
FIGURE 11.4 (a) Distribution of particle size, given as weight percentage; note that the highest
percentage of particles have a size between 75 and 90 m. (b) Cumulative particle-size distribution as a
function of weight. Source: After R.M. German.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Compaction
Upper punch
Compacted
shape
(green)
Powder
Feed
Shoe
Die
Lower punch
1.
2.
3.
Ejector
4.
(a)
Upper punch
P/M spur gear
(green)
Die
Core rod
Lower punch
(b)
Kalpakjian Schmid
ISBN No. 0-13-227271-7
FIGURE 11.5 (a) Compaction of metal powder to produce a

bushing. (b) A typical tool and die set for compacting a spur
gear. Source: Courtesy of Metal Powder Industries Federation.
Density vs. Compacting Pressure

1000 1200
0.29
0.3
s
Ten
200
Copper powder, coarse

Copper powder, fine
Iron powder, coarse
Iron powder, fine
2
1
0
0
20
40
60
80
Compacting pressure (tons/in2)
0.1
100
0
100
(a)
y
vit
t io
20
40
100
35
95
30
ga
Apparent
Density
3.49 g/cm3
1.44
2.75
1.40
150
nd
g th
on
Co
ti
uc
il e
n
s tr e
0.32
El
0.2
25
psi x 103
Density
of copper
Density
of iron
lb/in3
0.31
30
7
Density (g/cm3)
0.30
15
10
8.0
8.2
8.4
8.6
8.8
Sintered density (g/cm3)
90
25
85
20
80
Electrical conductivity (% IACS)
400
Elongation (%)
200
lb/in3
Tensile strength (MPa)
MPa
600
800
(b)
FIGURE 11.6 (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: After F.V. Lenel. (b) Effect of density on tensile strength, elongation,
and electrical conductivity of copper powder. (IACS is International Annealed Copper Standard for electrical conductivity.)

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Mechanics of Compaction
L/D = 1.66
700 MPa
600
500
400
300
200
100
(a)
(b)
(c)
(d)
D/ 2
C
L
(e)
p0
px
!r
dx
FIGURE 11.7 Density variation in compacting

metal powders in different dies: (a) and (c) singleaction press; (b) and (d) double-action press,
where the punches have separate movements.
Note the greater uniformity of density in (d) as
compared with (c). Generally, uniformity of
density is preferred, although there are situations
in which density variation, and hence variation of
properties, within a part may be desirable. (e)
Pressure contours in compacted copper powder
in a single-action press. Source: After P. Duwez
and L. Zwell.
Resultant pressure distribution:
!r
px + d p x
FIGURE 11.8 Coordinate system and stresses acting on an element in

compaction of powders. The pressure is assumed to be uniform across the
cross-section. (See also Fig. 6.4.)
Kalpakjian Schmid
ISBN No. 0-13-227271-7
px = poe4kx/D
Cold Isostatic Pressing

Upper cover
Cover
Wire
mesh basket
Pressure
vessel
Mold
seal plate
Metal
mandrel
Rubber
mold (bag)
Fluid
Pressure
vessel
Rubber
diaphragm
Pressing
rubber mold
Forming
rubber mold
Fluid
Powder
Powder
Pressure
source
Pressure
source
Lower
outside cover
Lower inside
cover
(a)
(b)
FIGURE 11.9 Schematic illustration of cold isostatic pressing in compaction of a tube. (a) The wet-bag process, where the rubber
mold is inserted into a fluid that is subsequently pressurized. In the arrangement shown, the powder is enclosed in a flexible
container around a solid core rod. (b) The dry bag process, where the rubber mold does not contact the fluid, but instead is
pressurized through a diaphragm. Source: After R.M. German.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Pressures and Capabilities

30
HIP
0.6
CIP
0.4
in.
Size (m)
20
P/F
0.2
10
P/M
PIM
1
2
3
4
5
Relative shape complexity
FIGURE 11.10 Process capabilities of part size

and shape complexity for various P/M
operations; P/F is powder forging. Source: Metal
Powder Industries Federation.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Metal
Aluminum
Brass
Bronze
Iron
Tantalum
Tungsten
Other Materials
Auminum oxide
Carbon
Cemented carbides
Ferrites
Pressure
MPa
psi 103
70275
400700
200275
350800
70140
70140
1040
60100
3040
50120
1020
1020
110140
140165
140400
110165
1620
2024
2060
1624
TABLE 11.1 Compacting Pressures for Various

Metal Powders
Hot Isostatic Pressing

Gas inlet
End cap
Pressure
Insulation
Heating coils
Workpiece
Temperature
Time
High-pressure
cylinder
Part
End cap
1. Fill can
2. Vacuum
bakeout
3. Hot isostatic press
4. Remove can
FIGURE 11.11 Schematic illustration of the sequence of steps in hot isostatic pressing. Diagram (4)
shows the pressure and temperature variation versus time.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Powder Rolling
Metal powder supply
Direction baffles
Hopper
Powder
Green sheet
Hot rolls
Shaping rolls
Coiler
Sintering furnace
Cooling
FIGURE 11.12 An example of powder rolling. The purpose of direction baffles in the
hopper is to ensure uniform distribution of powder across the width of the strip.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Spray Casting
Induction-heated
ladle
Atomizer
(nitrogen gas)
Particle injector
(optional)
Recipient
substrate
Tube
Deposition
chamber
FIGURE 11.13 Spray casting (Osprey process) in which molten metal is sprayed over a
rotating mandrel to produce seamless tubing and pipe.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Sintering
1.
R
1.
Neck formation
by vapor-phase
material transport
Neck formation
by diffusion
2.
2.
R
Distance between
particle centers
decreased, particles
bonded
3.
3.
(a)
(b)
TABLE 11.2 Sintering temperature and

time for various metal powders.
Kalpakjian Schmid
ISBN No. 0-13-227271-7
Particles bonded,
no shrinkage (center
distances constant)
FIGURE 11.14 Schematic illustration of two

basic mechanisms in sintering metal powders:
(a) solid-state material transport and (b)
liquid-phase material transport. R=particle
radius, r=neck radius, and =neck profile
radius.
Material
Copper, brass, and bronze
Iron and iron graphite
Nickel
Stainless steels
Alnico alloys (for permanent magnets)
Ferrites
Tungsten carbide
Molybdenum
Tungsten
Tantalum
Temperature ( C)
760900
10001150
10001150
11001290
12001300
12001500
14301500
2050
2350
2400
Time (min)
1045
845
3045
3060
120150
10600
2030
120
480
480
Effect of Temperature and Time

40
20
1
Elongation (%)
30
31
C
5
0
23
C(
0
5
2
2
C (2 0
0
2
11
10
4
(2
F
0
F)
5 0 F)
30
60
90
120
Sintering time (min)
(a)
150
112
0C
(205
0F)
20.4
12
30
C
20.8
21.2
15
13
Dimensional change from die size (%)
21.6
(22
50
F)
(2
40
0
F)
30
60
90
120
Sintering time (min)
150
(b)
FIGURE 11.5 Effect of sintering temperature and time on (a) elongation and (b) dimensional
change during sintering of type 316L stainless steel. Source: ASM International.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Mechanical Properties of P/M Materials

Designation
Ferrous
FC-0208
MPIF
type
N
R
S
FN-0405
S
T
Aluminum
601 AB
pressed bar
Brass
CZP-0220
T
U
W
Condition
Ultimate
Tensile
Strength
(MPa)
Yield
Strength
(MPa)
AS
HT
AS
HT
AS
HT
AS
HT
AS
HT
225
295
415
550
550
690
425
1060
510
1240
205
330
395
655
240
880
295
1060
45
95
70
35
80
40
72
39
80
44
AS
HT
110
252
48
241
165
193
221
76
89
103
Elongation
in 25 mm
(%)
Elastic
Modulus
(GPa)
< 0.5
< 0.5
1
< 0.5
1.5
< 0.5
4.5
1
6
1.5
70
70
110
110
130
130
145
145
160
160
60 HRH
75 HRH
6
2
55 HRH
68 HRH
75 HRH
13
19
23
Hardness
HRB
HRB
HRB
HRC
HRB
HRC
HRB
HRC
HRB
HRC
Titanium
Ti-6AI-4V
HIP
917
827
13
Superalloys
Stellite 19
1035
49 HRC
<1
Note: MPIF=Metal Powder Industries Federation; AS=as sintered; HT=heat treated;
HIP=hot isostatically pressed.
TABLE 11.3 Typical mechanical properties of selected P/M materials.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Titanium Property Comparison

Density
(%)
100
100
Yield Stress
(MPa)
840
875
Ultimate Tensile
Strength (MPa)
930
965
Elongation
(%)
7
14
Reduction of
Area (%)
15
40
875
875
975
8
9
14
14
17
26
Process
Cast
Cast and forged
Powder metallurgy
Blended elemental (P+S)
98
786
Blended elemental (HIP)

> 99
Realloyed (HIP)
100
880
P+S=pressed and sintered; HIP=hot isostatically pressed.

Source: After R.M. German
TABLE 11.4 Mechanical property comparison for Ti-6Al-4V titanium alloy.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
P/M Example: Bearing Caps
FIGURE 11.16 Powder-metal main bearing caps for 3.8- and 3.1-liter General Motors engines.
Source: Courtesy of Zenith Sintered Products, Inc., Milwaukee, WI.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Geometry for P/M Dies

Step requires up
to 12 taper to
assist ejection
0.250.50 mm parallel
surface to prevent
punch jamming
23 taper to
assist ejection
0.12 0.25 mm
parallel surface to
prevent powder
capture in die
Upper punch
Die
Workpiece
Maximum feasible taper

is 15 when bottom
compaction is employed
0.250.50 mm step
to prevent powder
capture in die
Lower punch
FIGURE 11.17 Die geometry and design features for powder-metal compaction.
Source: Metal Powder Industries Federation.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Poor
Poor
Good
Good
Fillet
radius
Sharp
radius
Design
Considerations
Fillet radius
Sharp radius
(a)
Sharp radius
(e)
Sharp
radius
Fillet radius
Fillet
radius
(b)
(f)
Acceptable
Die
Best
Punch
0.25 mm
(0.010 in.)
(min)
3045
Max 30
Can be
molded
Must be
machined
Workpiece
(g)
(c)
Upper
punch
0.25 mm
(0.010 in.)
(min)
Die
Acceptable, with additional operations
Feather edge
required on
punch
Flat
Hole must
be drilled
Workpiece
(d)

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Thread must be
machined
(h)
FIGURE 11.18 Examples of P/M parts,

showing various poor and good designs.
Note that sharp radii and reentry corners
should be avoided, and that threads and
transverse holes have to be produced
separately, by additional operations such
as machining or grinding. Source: Metal
Powder Industries Federation.
Design Considerations
Poor
Poor
Good
Good
Thicker flange
up to 12
r
Thin section
Taper to
assist ejection
Radius for ease
of ejection
Radius to reduce
likelihood of chipping
0.2H (max)
H
(a)
0.15H (max)
H
FIGURE 11.19 (a) Design features for

use with unsupported flanges. (b)
Design features for use with grooves.
Source: Metal Powder Industries
Federation.
(b)
Excessive
binder
Powder
build-up
Flow
direction
FIGURE 11.20 The use of abrupt transitions in molds

for powder injection molding causing non-uniform
metal-powder distribution within a part.
Kalpakjian Schmid
ISBN No. 0-13-227271-7
Mold
Excessive
binder
Process Comparison
Process
Casting
Advantages Over P/M

Wide range of part shapes and sizes
produced; generally low mold and
setup cost.
Forging (hot)
High production rate of a wide range

of part sizes and shapes; high mechanical properties through control of
grain flow.
High production rate of long parts;
complex cross-sections may be produced.
Wide range of part shapes and sizes;
short lead time; flexibility; good dimensional control and surface finish;
simple tooling.
Extrusion (hot)
Machining
Limitations as Compared With P/M

Some waste of material in processing;
some finishing required; may not be
feasible for some high-temperature alloys.
Some finishing required; some waste
of material in processing; die wear;
relatively poor surface finish and dimensional control.
Only a constant cross-sectional shape
can be produced; die wear; poor dimensional control.
Waste of material in the form of chips;
relatively low productivity.
TABLE 11.5 Competitive features of P/M and some other manufacturing processes.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Type
Oxide Ceramics
Alumina
General Characteristics
Zirconia
Carbides
Tungsten carbide
Titanium carbide
Silicon carbide
Nitrides
Cubic boron nitride
Titanium nitride
Silicon nitride
Sialon
Cermets
Nanophase ceramics
Silica
Glasses
Glass ceramics
Graphite
Diamond
High hot hardness and abrasion resistance, moderate strength and toughness; most
widely used ceramic; used for cutting tools, abrasives, and electrical and thermal
insulation.
High strength and toughness; resistance to thermal shock, wear, and corrosion;
partially-stabilized zirconia and transformation-toughened zirconia have better
properties; suitable for heat-engine components.
High hardness, strength, toughness, and wear resistance, depending on cobalt binder
content; commonly used for dies and cutting tools.
Not as tough as tungsten carbide, but has a higher wear resistance; has nickel and
molybdenum as the binder; used as cutting tools.
High-temperature strength and wear resistance, used for engines components and
as abrasives.
Second hardest substance known, after diamond; high resistance to oxidation; used
as abrasives and cutting tools.
Used as coatings on tools, because of its low friction characteristics.
High resistance to creep and thermal shock; high toughness and hot hardness; used
in heat engines.
Consists of silicon nitrides and other oxides and carbides; used as cutting tools.
Consist of oxides, carbides, and nitrides; high chemical resistance but is somewhat
brittle and costly; used in high-temperature applications.
Stronger and easier to fabricate and machine than conventional ceramics; used in
automotive and jet-engine applications.
High temperature resistance; quartz exhibits piezoelectric effects; silicates containing various oxides are used in high-temperature, nonstructural applications.
Contain at least 50% silica; amorphous structure; several types available, with a
wide range of mechanical, physical, and optical properties.
High crystalline component to their structure; stronger than glass; good thermalshock resistance; used for cookware, heat exchangers, and electronics.
Crystalline form of carbon; high electrical and thermal conductivity; good thermalshock resistance; also available as fibers, foam, and buckyballs for solid lubrication;
used for molds and high-temperature components.
Hardest substance known; available as single-crystal or polycrystalline form; used
as cutting tools and abrasives and as die insert for fine wire drawing; also used as
coatings.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Types of
Ceramics
and
Glasses
TABLE 11.6 Types and general

characteristics of ceramics and
glasses.
Ceramic Structure
Silicon ions
Oxygen ions
Aluminum ions
OH ions
FIGURE 11.21 The crystal structure of kaolinite, commonly known as clay;

compare with Figs. 3.2-3.4 for metals.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Properties of Ceramics
Transverse
Rupture
Compressive
Elastic
Strength
Strength
Modulus
Material
Symbol
(MPa)
(MPa)
(GPa)
Aluminum oxide
Al2 O3
140240
10002900
310410
Cubic boron nitride
cBN
725
7000
850
Diamond
1400
7000
8301000
Silica, fused
SiO2
1300
70
Silicon carbide
SiC
100750
7003500
240480
Silicon nitride
Si3 N4
480600
300310
Titanium carbide
TiC
14001900
31003850
310410
Tungsten carbide
WC
10302600
41005900
520700
Partially stabilized zirconia
PSZ
620
200
Note: These properties vary widely, depending on the condition of the material.
Hardness
(HK)
20003000
40005000
70008000
550
21003000
20002500
18003200
18002400
1100
Poissons
Ratio
()
0.26
0.25
0.14
0.24
0.3
Density
(kg/m3 )
40004500
3480
3500
3100
3300
55005800
10,00015,000
5800
TABLE 11.7 Approximate range of properties of various ceramics at room temperature.
Strength:
Elastic modulus:
Thermal conductivity:
UTS UTSoenP
E Eo(1 1.9P + 0.9P2)
k = ko(1 P)

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Temperature Effects
1.8
Ni-base
superalloy
600
1.0
500
Polyethylene
Nylon
Al alloys
ZrSiO4
(zircon)
0.8
0.6
SiC
0.2
400
High-purity SiC
SiC
300
200 Sialon 116
0
20.2
Glass ceramic
Low-density SiC
0
200
400
FIGURE 11.22
Effect of
temperature on thermal
expansion for several ceramics,
metals, and plastics. Note that
the expansions for cast iron and
for partially stabilized zirconia
(PSZ) are within about 20%.
80
70
50
40
20
10
0
600 800 1000 1200 1400 1600
Temperature (C)
200 400 600 800 1000 1200 1400 1600

Temperature (C)
FIGURE 11.23
Effect of
temperature on the strength
of various engineering
ceramics. Note that much of
the strength is maintained at
high temperatures; compare
with Figs. 2.9 and 8.30.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
400
90
30
Silicon nitride (reaction bonded)
2400
60
60
Al2O3
100
Lithium aluminum silicate
Fused
SiO2
2500
High-purity silicon nitride
Si3N4
0.4
2000
High-purity silicon nitride

(Fine grain)
Tensile strength (MPa)
Linear thermal expansion (%)
1.2
1000
Al2O3
1.6
1.4
500
800
F
1600
SiC
50
TiC
Al2O3
40
MgO
30
300
Si3N4
ThO2
20
200
SrO2
MgAl2O4
10
0
0
400
800
1200
Temperature (C)
100
0
1600
FIGURE 11.24
Effect of
temperature on the modulus
of elasticity for various
ceramics; compare with Fig.
2.9. Source: After D.W.
Richerson.
GPa
F
1500
Modulus of elasticity (psi x 106)
2.0
F
800 1200 1600 2000 2400 2800 3200
Partially
stabilized
Cast iron and MgO
ZrO
psi x 10 3
400
Example: Ceramic Bearings
(a)
(b)
FIGURE 11.25 A selection of ceramic bearings and races. Source: Courtesy of Timken, Inc.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Processes & Particle Production

FIGURE 11.26 Methods of crushing ceramics
to obtain very fine particles: (a) roll crushing, (b)
ball milling, and (c) hammer milling.
(a)
(c)
(b)
Process
Slip casting
Extrusion
Dry pressing
TA B L E 1 1 . 8
characteristics of
processing methods.
General
ceramics
Advantages
Large parts; complex shapes; low equipment cost.
Hollow shapes and small diameters; high
production rate.
Close tolerances; high production rate
with automation.
Wet pressing
Complex shapes; high production rate.
Hot pressing
Strong, high-density parts.
Isostatic pressing
Jiggering
Uniform density distribution.

High production rate with automation;
low tooling cost.
Complex shapes; high production rate.
Injection molding

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Limitations
Low production rate; limited dimensional
accuracy.
Parts have constant cross-section; limited
thickness.
Density variation in parts with high
length-to-diameter ratios; dies require
high abrasive-wear resistance; equipment
can be costly.
Limited part size and dimensional accuracy; tooling costs can be high.
Protective atmospheres required; die life
can be short.
Equipment can be costly.
Limited to axisymmetric parts; limited dimensional accuracy.
Tooling costs can be high.
Slip Casting
Trimming
knife
(a)
(b)
(c)
(d)
FIGURE 11.27 Sequence of operations in slip casting a ceramic part. After the slip
has been poured, the part is dried and fired in an oven to give it strength and
hardness. The step in (d) is a trimming operation. Source: After F.H. Norton.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
(e)
Doctor-Blade Process
Air (filtered)
in
Ceramic tape
on carrier tape
Drying
chamber
Exhaust
out
Slurry chamber and

doctor blade
Ceramic
slurry
FIGURE 11.28 Production of ceramic sheets through the

doctor-blade process.
Take-up
spool
Controller
for take-up
spool
Carrier film
Doctor blade
Ceramic film
Carrier film

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Density Variation in Compacts

Punch
L
= 1.75
D
90
0
10
Die
65
50
54
40
L
20
10
Punch
D
FIGURE 11.29 Density variation in pressed compacts in a single-action press. Note that the
variation increases with increasing L/D ratio; see also Fig. 11.7e. Source: After W.D. Kingery.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Extruding and Joggering

Water
To vacuum
Bat former
Jigger tool
Deairing Clay
chamber slug
Formed
ware
FIGURE 11.30 (a) Extruding and (b) jiggering

operations in shaping ceramics. Source: After R.F.
Stoops.
Extruder
Mold return
(a)
(b)
FIGURE 11.31 Shrinkage of wet clay, caused by

removal of water during drying; shrinkage may be as
much as 20% by volume. Source: After F.H. Norton.
Interparticle
water
(a)
Kalpakjian Schmid
ISBN No. 0-13-227271-7
Pore
water
(b)
Clay
particles
Dry
(c)
Glasses
Density
Strength
Resistance to thermal shock
Electrical resistivity
Hot workability
Heat treatability
Chemicals resistance
Impact abrasion resistance
Ultraviolet-light transmission
Relative cost
Soda-lime
Glass
High
Low
Low
Moderate
Good
Good
Poor
Fair
Poor
Lowest
Lead
Glass
Highest
Low
Low
Best
Best
Good
Fair
Poor
Poor
Low
Borosilicate
Glass
Medium
Moderate
Good
Good
Fair
Poor
Good
Good
Fair
Medium
TABLE 11.9 General characteristics of various types of glasses.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Fused
Low
High
Better
Good
Poor
None
Better
Good
Good
High
96% Silica
Glass
Lowest
Highest
Best
Good
Poorest
None
Best
Best
Good
Highest
Glass Sheet & Tubing

Controlled
Molten
atmosphere furnace
tin
Molten glass
Tube
Mandrel
Rollers
Furnace
Float bath
Lehr
FIGURE 11.32 The float method of

forming sheet glass. Source: Corning
Glass Works.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Rollers
FIGURE 11.33
Continuous manufacturing
process for glass tubing. Air is blown through the
mandrel to keep the tube from collapsing. Source:
Corning Glass Works.
Glass Bottles
Blow
head
Gob
Baffle
Air
Blank
mold
Neck
ring
Tip
Air
1. Gob falling into

blank mold
2. Gob in
blank mold
3. Blow down
in blank mold
4. Blow back in
blank mold
Air
Tongs
Blow
mold
Parison
5. Blank mold
reversed
6. Parison hanging on
neck ring, reheated
during transfer
7. Parison in
blow mold
8. Bottle blown,
cooling
9. Finished bottle
removed by tongs
FIGURE 11.34 Stages in manufacturing a common glass bottle. Source: After F.H. Norton.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Glass Pressing
1. Empty mold
2. Loaded mold
3. Glass pressed
4. Finished piece
FIGURE 11.35 Manufacturing steps for a glass item by pressing in a mold. Source: Corning Glass Works.
1. Empty mold
2. Loaded mold
3. Glass pressed
4. Finished
product
FIGURE 11.36 Pressing glass in a split mold. Note that the use of a split mold is essential to be
able to remove the part; see also Figs. 10.34, 10.35, and 10.36. Source: After E.B. Shand.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Residual Stresses in Glass

Step 1
Step 2
Step 3
Thickness
1. Hot glass,
no stresses.
2. Surface cools quickly,

surface contracts,
center adjusts, only
minor stresses.
3. Center cools,
center contracts,
surface is compressed,
center in tension.
(a)
Compression
Tension
Residual stresses
(b)
FIGURE 11.37 Stages in the development of residual stresses in tempered glass plate.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Metal-Matrix Composites
Fiber
Graphite
Boron
Alumina
Silicon carbide
Molybdenum, tungsten
Matrix
Aluminum
Magnesium
Lead
Copper
Aluminum
Magnesium
Titanium
Aluminum
Lead
Magnesium
Aluminum, titanium
Superalloy (cobalt base)
Superalloy
Typical Applications
Satellite, missile, and helicopter structures
Space and satellite structures
Storage-battery plates
Electrical contacts and bearings
Compressor blades and structural supports
Antenna structures
Jet-engine fan blades
Superconductor restraints in fusion power reactors
Storage-battery plates
Helicopter transmission structures
High-temperature structures
High-temperature engine components
High-temperature engine components
TABLE 11.10 Metal-matrix composite materials and typical applications.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Example: Brake Caliper
FIGURE 11.38 Aluminum-matrix composite brake caliper, using nanocrystalline alumina-fiber reinforcement.
Source: Courtesy of 3M Specialty Materials Division.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Powder-in-Tube Process
Superconducting
ceramic
powder
Hopper
High-purity
silver tube
Wire
1. Fill
2. Pack
3. Extrude/Draw
Strip
4. Roll
FIGURE 11.39 Schematic illustration of the steps involved in the powder-in-tube process. Source:
Courtesy of Concurrent Technologies Corporation.

Kalpakjian Schmid
ISBN No. 0-13-227271-7
Case Study: Engine Valves

Steel shaft
Tungsten-carbide
wear face
Copper interlayer
Steel cap
FIGURE 11.40 A valve lifter for heavy-duty diesel engines, produced from a hot-isostatically-pressed
carbide cap on a steel shaft. Source: Courtesy of Metal Powder Industries Federation and Bodycote,
Inc.

Kalpakjian Schmid
ISBN No. 0-13-227271-7

Ch11 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ch11 PDF

Uploaded by

Copyright:

Available Formats

P/M Parts

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Particle Size Distribution

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 11.5 (a) Compaction of metal powder to produce a

Density vs. Compacting Pressure

Copper powder, coarse

Electrical conductivity (% IACS)

Tensile strength (MPa)

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 11.7 Density variation in compacting

Resultant pressure distribution:

FIGURE 11.8 Coordinate system and stresses acting on an element in

Cold Isostatic Pressing

Manufacturing Processes for Engineering Materials, 5th ed.

Pressures and Capabilities

FIGURE 11.10 Process capabilities of part size

Manufacturing Processes for Engineering Materials, 5th ed.

TABLE 11.1 Compacting Pressures for Various

Hot Isostatic Pressing

3. Hot isostatic press

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

TABLE 11.2 Sintering temperature and

FIGURE 11.14 Schematic illustration of two

Effect of Temperature and Time

Dimensional change from die size (%)

Manufacturing Processes for Engineering Materials, 5th ed.

Mechanical Properties of P/M Materials

TABLE 11.3 Typical mechanical properties of selected P/M materials.

Manufacturing Processes for Engineering Materials, 5th ed.

Titanium Property Comparison

Blended elemental (HIP)

P+S=pressed and sintered; HIP=hot isostatically pressed.

TABLE 11.4 Mechanical property comparison for Ti-6Al-4V titanium alloy.

Manufacturing Processes for Engineering Materials, 5th ed.

P/M Example: Bearing Caps

Manufacturing Processes for Engineering Materials, 5th ed.

Geometry for P/M Dies

Maximum feasible taper

Manufacturing Processes for Engineering Materials, 5th ed.

Acceptable, with additional operations

Manufacturing Processes for Engineering Materials, 5th ed.

FIGURE 11.18 Examples of P/M parts,

FIGURE 11.19 (a) Design features for

FIGURE 11.20 The use of abrupt transitions in molds

Advantages Over P/M

High production rate of a wide range

Limitations as Compared With P/M

Manufacturing Processes for Engineering Materials, 5th ed.

Manufacturing Processes for Engineering Materials, 5th ed.

TABLE 11.6 Types and general

FIGURE 11.21 The crystal structure of kaolinite, commonly known as clay;

Manufacturing Processes for Engineering Materials, 5th ed.

TABLE 11.7 Approximate range of properties of various ceramics at room temperature.

E Eo(1 1.9P + 0.9P2)

Manufacturing Processes for Engineering Materials, 5th ed.

200 Sialon 116

200 400 600 800 1000 1200 1400 1600

Manufacturing Processes for Engineering Materials, 5th ed.

Silicon nitride (reaction bonded)