POWDER METALLURGY

PROCESS
Rona Mae L. Taduyo
Three Major Steps
1. ●
Blending and mixing (of powders)

2. ●
Compaction

3. ●
Sintering
* Optional and finishing secondary operations

Powder Metallurgy
Blending and Mixing

Blending
– mixing powder of the same chemical composition but different sizes.

Mixing
– combining powders of different chemistries.

Powder Metallurgy
Blending and mixing are accomplished by mechanical means:

Powder Metallurgy
Except for powders, some other ingredients are usually added:

Lubricants:
to reduce the particles-die friction
Binders:
to achieve enough strength before sintering
Deflocculants:
to improve the flow characteristics during feeding

Powder Metallurgy
Compaction
Pressing process
Blended powders are pressed in dies under high pressure to form them
into the required shape. The work part after compaction is called a green
compactor simply a green, the word green meaning not yet fully processed.

Pressure: Pressureless:
Cold Isostatic Pressing Slip Casting
Hot Isostatic Pressing Gravity Compaction
High Energy Rate Techniques Continuous Pressureless
Vibratory Compaction Technique
Continuous Compaction
Forging or Extrusion

Powder Metallurgy
Compaction - Pressure
COLD ISOSTATIC PRESSING
- Placement of powder in flexible rubber mold
- Hydrostatic pressurization in chamber by water
- Most common pressure of 400 MPa
Typical Application: Automotive cylinder liner

Powder Metallurgy
Cold Isostatic Pressing

Powder Metallurgy
HOT ISOSTATIC PRESSING
- powder container is usually made up of high melting point
sheet metal
Pressurizing media: inert gas
Common condition: 100 MPa, 1100°C
Advantages: Compacts of 100% density, good metallurgical
bonding, good mechanical properties
Limitations: wider dimensional tolerances, greater cost &
time

Powder Metallurgy
Hot Isostatic Pressing

Powder Metallurgy
HIGH ENERGY RATE TECHNIQUES
- Explosive or spark discharge methods are applied in
closed die
- Short time & high pressures
High punch & die wear, limited tolerances, high cost

VIBRATORY COMPACTION
- Simultaneous application of pressure & vibration
- Use of much lower pressures
- Complicated equipment design

Powder Metallurgy
CONTINUOUS COMPACTION
- Applied to simple shapes (rod, sheet, tube, plate etc)
- Flowing loose powder between a set of vertically oriented
rolls at much lower speed

Powder Metallurgy
Continuous Compaction

Powder Metallurgy
FORGING or EXTRUSION
• Canning of powder
• Heating or evacuation of sealed container followed by forging
or evacuation
• Mechanical or chemical removal of container material

Powder Metallurgy
Typical Compaction Pressure for
Various Applications

Powder Metallurgy
Compaction - Pressureless
SLIP CASTING
- Preparation of slip (powder suspended in liquid and additives)
- Keeping slip in mold made up of fluid absorbing material
- Formation of slip casting
- Removal of slip followed by drying operation

Powder Metallurgy
CONTINUOUS PRESSURELESS TECHNIQUE
- Application of powder in the form of slurry
- Consolidation and drying
- Used to produce porous sheets for electrodes of nickel-
cadmium batteries

Powder Metallurgy
Sintering
Compressed metal powder is heated in a controlled-
atmosphere furnace to a temperature below its melting point,
but high enough to allow bounding of the particles.
Purpose - to increase strength & hardness of a green compact
Principal variables – temperature ( generally within 70 – 90% of
the melting point of metal or alloy), time (10 min. – 8 hours) &
furnace atmosphere
Sintering process is concerned with
– diffusion (surface of particles as temperature rises)
– densification (decreases porosity, increases particle contact
area)
– recrystallization & grain growth (between particles at the
contact area) Powder Metallurgy
The primary driving force for sintering is not the fusion of material, but formation
and growth of bonds between the particles, as illustrated in a series of sketches
showing on a microscopic scale the changes that occur during sintering of metallic
powders.

Powder Metallurgy
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Powder Metallurgy
FINISHING / SECONDARY OPERATIONS
1. Sizing – cold pressing to improve dimensional accuracy
2. Coining or pressing - cold working process, to press details into
surface
- condensation of sintered product
3. Impregnation - impregnation with heated oil (self lubricated bearings)
- oil fills the pores of the part
4. Infiltration - placement of slug of a lower melting point metal against
the sintered part
- infiltration of molten metal by capillary action
- pores are filled with a molten metal
5. Heat treatment , Plating, Painting

Powder Metallurgy
 Elemental or Alloy Additives
metal powders (lubricants or binders)

Blending and
Mixing

Compacting

Sintering

Optional Secondary Optional Secondary

Manufacturing Finishing

Finished Powder
Metallurgy Product
Powder Metallurgy
Finished Powder Metallurgy
Products Powder Metallurgy
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THE
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