Powder Metallurgy

SUBMITTED BY
INDRESH KUMAR BAIS
ROLL NO. 11031M02018
 Outline

Introduction
Powder Manufacturing
Powder Metallurgy Process
Sintering
Other Powder Metal Processes
Powder Metal Products
Powder Metallurgy Design
 Introduction

Powder metallurgy is a process by

which fine powdered materials are
blended, pressed into a desired
shape, and then heated to bond
surfaces
Typically used when large
amounts of small, intricate parts
with high precision are required
Little material waste and unusual
mixtures can be utilized
Used for parts in the automotive
industry, household appliances,
and recreational equipment
Powder Metallurgy

Metal

Powder

Metal Product
 Examples of Powder
Metal Products
Gears
Cams
Cranks
Bearings
Roller bearing cages
Housings
Light bulb filaments
Sprinkler mechanisms
Powder Metallurgy
Process
 Powder Manufacturing

Conversion of molten metal to

powder

Atomization
Powder Metal Materials

Elemental
A pure metal, most commonly
iron, aluminum or copper

Prealloyed
An alloy of the required
composition, most commonly
copper alloys, stainless steel
or high-speed steel
 Powder Manufacturing

Other methods of producing

powder:
- Chemical reduction of
particulate compounds
- Electrolytic deposition
- Pulverization or grinding of
brittle materials
- Thermal decomposition
- Precipitation from solutions
- Condensation of metal vapors
Atomization
Atomization is accomplished by forcing a molten
metal stream through an orifice at moderate
pressures. A gas is introduced into the metal stream
just before it leaves the nozzle, serving to create
turbulence as the entrained gas expands (due to
heating) and exits into a large collection volume
exterior to the orifice. The collection volume is filled
with gas to promote further turbulence of the molten
metal jet. On Earth, air and powder streams are
segregated using gravity or cyclonic separation.
Most atomised powders are annealed, which helps
reduce the oxide and carbon content. The water
atomized particles are smaller, cleaner, and
nonporous and have a greater breadth of size, which
allows better compacting. The powders produced
through this method are normally of spherical or
pear shape. Usually, they also carry a layer of oxide
over them.
 Blending and Mixing

Blending
Combining powders of the same material
but possibly different particle sizes

Mixing
Combining powders of different materials
 Compaction

High pressure is applied to squeeze

the powder into the desired shape
 Sintering

Heats the powder below the melting

point to allow solid-state diffusion
and bond the particles together
Sintering
 Other Powder Metal
Processes
Cold Isostatic Pressing
Hot Isostatic Pressing
Injection Molding
Powder Rolling
Powder Extrusion
Plasma Spraying
 Injection Molding

The powder is mixed with a binder

and molded, and the binder is
removed before sintering
 Powder Rolling

Powder is compressed in a rolling mill

to form a strip
Powder Metal Products

1. Porous or permeable
products
2. Products of complex shapes
3. Products made of materials
that are difficult to machine or
have high melting points
4. Products which require the
combined properties of
multiple materials
5. Products in which powder
metallurgy produces superior
properties
 Powder Metallurgy
Design
1. The shape must permit removal
from the die
2. The shape should not have thin
walls or sharp corners
3. The shape should permit the
construction of strong tooling
4. The shape of the part should be
within the thickness range for
which the powder can be properly
compacted
5. The part should have as few
changes in section thickness as
possible
 Powder Metallurgy
Advantages
1. Elimination/reduction of
machining
2. High production rates
3. Complex shapes can be
produced
4. Wide composition variations
are possible
5. Wide property variations are
possible
6. Scrap is eliminated or
reduced
 Powder Metallurgy
Disadvantages
1. Inferior strength properties
2. Relatively high die cost
3. High material cost
 APPLICATION

•Bearing and filtering

•Complex shape
components
•Automotive
components
•Grinding wheel