MDJ13303 – Manufacturing Process I Laboratory Module

Semester 2 2021/2022

LABORATORY REPORT
Course Name Manufacturing Process 1

Course Code MDJ13303 Lab No. 2

Semester SEMESTER 2 SA 2021/2022

Title of Experiment POWDER METALLURGY

Date of Experiment 7/3/2022

Date of Submission 14/3/2022

Instructor’s Name En Muhamad Nur Bin Misbah

(Name and Matric No)

NUR ANISA WASILAH BINTI MOHD NOOR SHAHRIN - 212051542

Marks
Objectives 5
Introduction 20
Methodology 10
Results & Discussions 45
Conclusions 15
Others (Format, References, Appendix) 5
TOTAL 100

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MDJ13303 – Manufacturing Process I Laboratory Module
Semester 2 2021/2022

LAB MODULE

COURSE NAME Manufacturing Process 1

COURSE CODE MDJ13303 LAB No. 2

Powder Metallurgy

Faculty of Mechanical Engineering

Technology

LEVEL OF COMPLEXITY

1 2 3 4 5 6

KNOWLEDGE REPETITION APPLICATION ANALYSIS EVALUATION SYNTHESISE

√ √ √ √

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MDJ13303 – Manufacturing Process I Laboratory Module
Semester 2 2021/2022

POWDER METALLURGY LABORATORY

1.0 OBJECTIVE

1. To expose the students powder metallurgy technology in manufacturing.

2. To study powder metallurgy process and product.

2.0 INTRODUCTION

Powder metallurgy is the process of blending fine powdered materials, pressing them into a
desired shape or form (compacting), and then heating the compressed material in a controlled
atmosphere to bond the material (sintering).

The powder metallurgy process typically consists of the following operations, in sequence:
i. Powder iii. Compactio v. Finishing
production n
ii. Blending iv. Sintering

Fig 1: Flow of powder metallurgy process.

Compaction is the step in which the blended powders are pressed into various shapes in dies.
The purpose of compaction are to obtain the required shape, density and particle-to-particle
contact and to make the part sufficiently strong for further processing. The pressed powder is
known as green compact, since it has a low strength. The density of the green compact
depends on the pressure applied.

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 MDJ13303 – Manufacturing Process I Laboratory Module
Semester 2 2021/2022

Sintering is the process whereby green compacts are heated in a controlled atmosphere
furnace to a temperature below melting point, but sufficiently high to allow bonding (fusion)
of the individual particles.

Fig 2: Two mechanisms of sintering metal powders (a) solid state material transport (b) vapor-
phase material transport

Powder metallurgy is useful in making parts that have irregular curves, or recesses that are
hard to machine. It is suitable for high volume production with very little wastage of material.
Secondary machining is virtually eliminate.

Fig 3: Typical parts that can be made with this process include cams, ratchets, sprockets, pawls, and
carbide tooltips.

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MDJ13303 – Manufacturing Process I Laboratory Module
Semester 2 2021/2022

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MDJ13303 – Manufacturing Process I Laboratory Module
Semester 2 2021/2022

3.0 MATERIAL & EQUIPMENT

1. Aluminium powder
2. Densimeter

3. Hand Press

4. Die set

5. Vernier caliper

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 MDJ13303 – Manufacturing Process I Laboratory Module
Semester 2 2021/2022

4.0 PROCEDURE

1. Weighting 4 g metal powder using densimeter.

2. Fed the metal powder into the die.
3. Compact the metal powder using hand press.
4. Take out the specimen from the die.
5. Measure the thickness of the specimen.
6. Check the specimen density using densimeter.
7. Record the data.

5.0 RESULTS AND DISCUSSIONS

DISCUSSIONS :

1. Define powder metallurgy process.

- Powder metallurgy processes is a process where metal powders are compacted into desired
and complex shapes and sintered (heating without melting) to form a solid shape. A wide
range of parts and components are made by powder metallurgy techniques: automotive
component (piston rings, connecting rods, brake pads, gears, cam and bushing.

2. List the sequences of powder metallurgy process.

- Powder production
- Blending
- Compaction
- Sintering
- Finishing
3. Name the equipment below.

- Die Set

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4. Describe compaction process.

- The powder, called feedstock, is fed into the die by feed shoe, and the upper punch
descend into the die. The presses used are actuated either by hydraulically or
mechanically, and the process generally is carried out at room temperature. The
pressed powder is known as green compact, because it has low strength. The green
parts are very fragile, and can easily crumbled or become damaged. The density of
the green compact depends on the compacting pressure. The higher the density of the
compacted part, the higher are its strength and elastic modulus.
5. Describe the purpose of compaction process.

- The purpose of compaction process is to obtain the required shape, density, and
particle-to-particle contact and to make the part sufficiently strong for further
processing.
6. Define green density.

- The pressed powder is known as green compact or green density, because it has low
strength. The green parts are very fragile, and can easily crumbled or become
damaged also green density is the ratio of metal powder volume to the external
volume of the printed part, and is a measure of how tightly packed the powder
particles in the printed part are.
7. Explain sintering process.
- Sintering is the process whereby green compact are heated, in a controlled
atmosphere furnace, to a

temperature below the melting point of the metal, but sufficiently high to allow
bonding (fusion) of the individual particles to impart strength to the part.

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8. Illustrate the mechanisms of solid state material transport in sintering metal powders.

5.0 CONCLUSIONS
In the conclusions, The higher compaction pressures contribute to an increase in density and
neck contact size in green compact, while reducing the rate of neck growth during sintering.
Further, the higher compaction pressures lead to larger net neck sizes. Also, the shrinkage
decreases with an increasing compaction pressure. It is the sintered neck size which dominates
the properties such as strength and ductility, thus, higher compaction pressures are generally
beneficial. Increasing the compaction pressure gives better dimensional control, less sintering
shrinkage, and better final properties.

6.0 REFERENCES

1. S. Kalpakjian, S.R. Schmid (2001). Manufacturing Engineering and

Technology. 4th Ed. Prentice Hall International
2. http://en.wikipedia.org/wiki/Powder_metallurgy