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Lecture 02
Credits 3 (3-0-0)

Instructor: Dr. Sagar Sarkar

Friday (11:00 AM-12:00 PM) – Slot F

Production of Metallic Powders
Near Net Shape Manufacturing (MCL133)

1
 Recap

• What is need for study the powder metallurgy?

• Relevance to the modern manufacturing processes

• Application wise

• Specific materials (say magnetic materials)

• A brief history of powder metallurgy

• Overview of the topics to be covered

2
 How to produce metal powders

• Solid-State Reduction
• Atomization (gas/water)
• Electrolysis
• Chemical

Which method to use?

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 Solid-State Reduction
(a) Roll crusher (b) Ball mill

Double roll crusher Single roll crusher

https://www.youtube.com/watch?v=MaKjOySPd1g
https://www.youtube.com/watch?v=r0XZTIWXQ3M

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 Solid-State Reduction
Ball & Rod Mill operations https://www.youtube.com/watch?v=bljhXsH8-ME

Vibratory Disc Mill operations https://www.youtube.com/watch?v=aD_9Ti3RxQ0

Tiltable Ball & Rod Mill operations https://www.youtube.com/watch?v=Uds_533gS7Q

Laboratory Digital Ball Mill

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 Atomization (gas/water)
 Produce a liquid-metal stream by injecting molten metal through
a small orifice

 Stream is broken by jets of inert gas, air, or water

 The size of the particle formed depends on:

• Temperature of the metal

• Metal flowrate through the orifice
• Pressure of jet
• Nozzle size and jet characteristics

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 Atomization (gas/water)
The process consists of main three stages

• Melting
• Atomization
• Solidification and cooling

 Melting is done by induction, arc, plasma or electron-beam

technique to maintain purity of melt.
 Atomization is done by high velocity water, compressed air or inert
gas.
 The disintegrated particles are solidified in controlled atmosphere,
vacuum , air or water.
Main two types of techniques: Water Atomization, Gas Atomization

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Gas atomization

https://www.youtube.com/watch?v=ndZoucUHrtc
https://www.youtube.com/watch?v=vouCR6bhCt0

8
 Water/liquid atomization

https://www.youtube.com/watch?v=bQnQvCk9x6E

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 Electrolysis
• Electrolyte composition and concentration, temperature, and current
density

• Further processing such as washing, drying, reducing, annealing, and

crushing is often required,

• Yields high-purity and high-density powders.

• Copper , iron, chromium, and magnesium powders are also produced this
way.

• Due to its associated high energy costs, electrolysis is generally limited to

high-value powders such as high-conductivity copper powders.

https://www.youtube.com/watch?v=3X9c6epL7HQ

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 Chemical
• Oxide reduction, Precipitation from solutions, and Thermal
decomposition.

• The powders produced can have a great variation in properties and yet
have closely controlled particle size and shape.

• Oxide-reduced powders are often characterized as "spongy," due to pores

present within individual particles.

https://www.youtube.com/watch?v=iP1Im4QILS0

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 Chemical
• Solution-precipitated powders can provide narrow particle size distributions
and high purity.

https://en.wikipedia.org/wiki/Precipitation_(chemistry)

• Thermal decomposition is most often used to process carbonyls. These

powders, once milled and annealed, exceed 99.5% purity.

https://www.youtube.com/watch?v=BQymwRKKTTM

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 Have a look

Conventional Press-and-Sinter Powder Metallurgy

https://www.youtube.com/watch?v=I39m28NZ7_s

https://www.coursera.org/lecture/aerospace-materials/5-1b-methods-for-
producing-powder-materials-part-2-NN1lP

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Thank you

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