Project 1

Average 82%
Range 52-95
Top Teams

95% Team 1
95% Team 11
93% Team 21
91% Team 15
91% Team 4
90% Team 10

The Industrious Mechys

Tainted Monkey
Future of Engineering
Captain Crunch and the Cereal Killers
Mountaineers
The Mountaineers
1

CHAPTER-11
POWDERPROCESSING
PROCESSING
POWDER

Advantages:
Produces a high yield compared to other primary
processing methods - usually over 95 percent.
Complex and thin shapes can be produced
relatively easily.
Few machining operations are required, because
the part already has a good finish.
High production levels and good reproducibility.
3

Process Limitations
Tooling costs are high - because high pressures are
involved and product shapes are intricate.
Material cost are high - because the powder form is
more costly than bars, sheets, etc.
Mechanical properties (such as strength) are lower if
the part is not 100 percent dense.
Solid state shrinkage will occur during sintering and
cooling.

Design Limitations
Small, intricate shapes produced - maximum weight of 70 lbs.
Uniform sections preferred - grooves, tapers, and threads are
generally not possible (since powder cannot be compacted to
uniform density).
Minimum section thickness is 0.06 in (1.5mm).
Length/diameter ratio should be under 5 for cylinders.
Thin shapes, two dimensional best (gears, knife blades, etc.)
5

Design Considerations
The total volume of the part
VT = Va +Vb + Vc+ void space.
Where
VT = Total volume of part.
Va = Volume of part from material A.
Vb = Volume of part from material B.
Vc = Volume of part from material C.
void space = volume of part not filled.
The total weight of the part
MT = Ma + Mb + Mc.
Where
MT=Total weight of part.
Ma=Weight of part due to material A.
Mb= Weight of part due to material B.
Mc= Weight of part due to material C.

 Volume of the part

Vx = Mx / dx
Where:
Vx = volume of material X in final component
Mx = Mass of material X
dx = density of material X
But Mass of Material X is
Mx = WFx*M
WFx = weight fraction of material X
M = Total mass of part M

 The Total Material cost would be the sum of

the individual mass components times their
respective unit costs.
CU=(Ca*Ma)+(Cb*Mb)+(Cc*Mc).
The strength of the component can be
estimated by means of the volume fraction.

Example -1

10 10

11 11

12 12

13 13

14 14

15 15

16 16

Example -2

17 17

18 18

19 19

Summary
Virtually unlimited choice of alloys, composites, and associated
properties.
Refractory materials are popular by this process.
Controlled porosity for self lubrication or filtration uses.
Can be very economical at large run sizes (100,000 parts).
Long term reliability through close control of dimensions and
physical properties.
Very good material utilization.
Limited part size and complexity
High cost of powder material.
High cost of tooling.
Less strong parts than wrought ones.
Less well known process.
20

Homework
HW 8 Due Tuesday, September 30
Problem 1. Work problem 11-7 with the final
volume of the part = 8 in3 and will be 85% dense. All
other data remains the same. Problem 11-7 is
similar to Example problem 11.1.
Problem 2. The density of a part is increased to 98%
from 72% and the original part shape was 6.0 in x 3.0
in x 2.0 in. What are the final part dimensions? This
problem similar to Example problem 11.2.

21