Sintering/Powder Metallurgy

Process overview
ARUN T S

Internal Knowledge Document | July 06, 2020

 Last Modified 1/23/2019 10:51 PM India Standard Time Printed 1/24/2019 9:01 AM India Standard Time
Basic Design Rules
Powder Metallurgy
Process Overview
Cost overview
Sintering Technology

References
Powder metallurgy is a powder based compacting method for achieving
complex designs with little or no machining processes

Last Modified 1/23/2019 10:51 PM India Standard Time

Manufacturing process description

▪ Powder metallurgy (PM) is a term covering

a wide range of ways in which materials or
components are made from metal powders.

▪ PM processes can avoid, or greatly reduce,

the need to use metal removal processes.

▪ Thereby drastically reducing yield losses in

Printed 1/24/2019 9:01 AM India Standard Time

manufacture and often resulting in lower
costs.

▪ It is very widely used in industry for tools of

many types and globally ~ 50,000t/yr is made by
PM

▪ The powder metallurgy process generally consists

of three basic steps: powder blending
(pulverisation), die compaction, and sintering.

▪ These processes are followed by machining

& finishing operations is required.

McKinsey & Company 2

Benefits of powder metallurgy process over conventional manufacturing
process

Tensile strength
Material yield Energy consumption / kg Dimensional accuracy
(MPa)

Tensile strength low

Energy requirement 2,000
Raw material Manufacturing Manufacturing per kg of finished Forging

mediumhigh
1,500
utilization process process part
1,000 Casting

Machining
95 Sintering Sintering 29 500 P/M
Stam- Fine
90 Casting Casting 30-38 0 ping blanking

Injection moulded

Machining steels
Sintered steels
Cast zinc alloys
Plastic
75-80 Forging Forging 46-49

Forged steels
very low medium high very

Cast iron
40-50 Machining Machining 66-82 low

plastics
high

alloys
(%) 75 50 25 0 0 25 50 75 (MJ) Accuracy
0

▪ High RM yield ▪ Energy Saving Technology ▪ RM flexibility ▪ High repeatability

▪ Near net shape technology ▪ Cost efficient ▪ Wide range of Mechanical ▪ Close tolerances
Properties
▪ High repeatability ▪ Good Surface Finish
▪ Light weight
▪ Cost efficient
▪ Lesser Lead time
Sintered parts are being used for various
applications
PM Market share Weight (Kg) per vehicle sintered parts by country
USA Japan China
Automotive
4.8 W. Europe Brazil
Appliances 25
%1.7%
Hand tools 20
23.3% 0. 3
% Motocycles 15
Other
10
69.9%
5
0
1990 95 00 05 10
15

Typical components used in Passenger vehicles

Steering
Fuel Injection Eg: CAM
Eg: Control Sleeve, discs
Pulleys

Engine
Eg: Sprockets, Valve
seats / guides

Brake Disc
Alternator
Eg : Hubs &
Eg : Reduction Shock
Pad
Gears, Ring Absorber
gears Eg: Piston, Rodguide,
Transmission
Cylinder ends
Eg : Synchronizer
Hubs
Product Variants – Engine Application

Pulley - Crankshaft Pulley - Camshaft Cam Pulley Assy Rotor – Engine Oil Pump

Pulley – Fuel Injection Sprocket – VVT Timing Camshaft - Hub Assembly Bearing Cap – Cylinder

Rotor Shaft Assy. - VVT Bracket – Water Pump Valve Guide & Valve Seats Rotor – Vacuum Pump
Product Variants – Transmission Application

Synchronizer Hubs – LT Synchronizer Hubs - HT Synchro Hub – Dual Gear Synchro Keys - Poppets

Gear Shifter – Pin (PV) Gear Shifter – Plate (PV) Gear Shifter – Arm (2W) Rotor – Transmission OP
Product Variants – Suspension application

Suspension for Passenger vehicles & Commercial vehicles

Piston rod
guides

Piston
Valve

Seperator
piston
Sintering Technology

Powder Metallurgy
Process Overview
Cost overview
Basic Design Rules
References
Sintering – Typical Process Flow

A
A Base Iron powder is manufactured from
C materials taken from Ore, Scrap and
B other sources.

B Alloying elements are mixed together in fine

proportion to make a homogeneous
mixture.
D
C The alloy powder is pressed to form a
mechanical bonding between atoms
of powders.

D The pressed part is treated in heat at

a certain temperature to for
metallurgical bonding.
A Process – Iron Powder manufacturing
In the sponge iron process,
▪ High purity magnetite iron ore is reduced to pure iron in a
high temperature tunnel kiln through a solid state reduction
process.
▪ Sponge iron powders are irregular in shape and
characterized by a high degree of interconnected porosity.
▪ This results in extremely high strength and modest
compressibility.
In the water atomization process,
▪ A stream of molten iron is disintegrated into powder by
high pressure water jets
▪ The powder produced in this fashion is dried and then
annealed in Hydrogen to remove oxygen introduced by
the atomizing process
▪ The atomized particles are rounded in shape and
have little or no internal porosity
A Raw Material – Elemental Composition
RM constituents (%)
Market
S.No Common Name share Iron Carbon Copper Nickel Moly Chrome Manganese

1 Carbon Steel 5% Rest 0.3-0.9

2 Copper Steel 30% Rest 0.3-0.9 1.5-11.0

3 Nickel Steel 10% Rest 0.3-0.9 0.2-2.5 1-5.5

4 Pre Alloyed Steel 10% Rest 0.4-0.8 0.35- 0.4-1.7 1.3-2.7 0.05-0.55
2.05

5 Hybrid Low alloy steel 15% Rest 0.3-0.7 1.0-7.0 0.4-0.95

8 Copper Infiltrated steel 5% Rest 0.3-0.9 8-25.0

6 Sinter Hardened Steel 10% Rest 0.5-0.9 1.0-3.0 1.0-7.0 0.4-1.4 0.05-0.50
A Raw Material – Mechanical Properties (With & Without HT)
Yield Strength Ultimate Tensile Young's
(Mpa) strength (Mpa) Modulus (Gpa) Hardness Density (g/cc)
S.No Common Name Min Max Min Max Min Max Min Max Min Max
1 90 260 120 390 105 140 40 HRF 70 6.1
Carbon Steel HRB
2 -- -- 410 660 7
115 150 20 HRC 35 HRC
3 140 480 170 570 6.6 7.2
Copper Steel 95 130 60 HRF 65 HRB
4 -- -- 480 720 6 7.2
110 150 99 HRB 60
5 120 410 170 550 HRC 6.2 7.1
Nickel Steel
6 -- -- 620 115 155 55 HRF 87 6.6 7.4
1,280 HRB
7 290 900 6.6 7.4
Pre Alloyed Steel 360 115 170 23 HRC 40
8 -- -- 1,100 6.8 7.3
HRC
9 450 780 620 6.55 7.3
130 160 60 HRB 33
Hybrid Low alloy steel 1,280
10 -- -- HRC
6.7 7.3
480 115 160 28 HRC 60
11 Sinter Hardened Steel -- -- 860 6.7 7.4
HRC
760 120 160 81 HRB 98 6.6 7.2
12 360 590
Diffusion Alloyed steel 1,650 HRB
13 -- -- 6.65 7.35
410 120 170 25 HRC 60
1,280 HRC 6.65 7.35
Copper Infiltrated steel 220 480
14 470 115 155 98 HRB 57
(Copper - 8% to 25%) 7.35 8.2
-- -- 690
970 830 145
HRC 160 36 HRC 55 HRC 7.35 8.2

720 125 170 72 HRB 25

1,170 HRC

125 165 28 HRC 55

B Process – Blending
Mixing different elemental powder to make required Raw material for particular Product

BASE
POWDER

ALLOYING ELEMENTS
Types of Blenders

(a) Rotating drum (b) Double cone (c) Screw Mixer (d) Blade Mixer
C Process – Compaction

Blended powders are passed through die under gravity to form them into the required shape and bonded together
mechanically. The product after compaction is called a Green Compact which signifies that the product is yet to be processed.

Typical steps in compaction

Tool and die set for compaction

D Process – Sintering

(a) Time-Temperature curve for sintering (b) Schematic cross-section of a continuous sintering
furnace

Compressed metal powder is heated in a controlled-atmosphere furnace to a temperature below its melting point, but high
enough to allow bonding of the particles metallurgically. Temperature of sintering zone ranges from 800°C to 1200 °C.
Sintering Technology

Powder Metallurgy
Process Overview
Cost overview
Basic Design Rules
References
Conversion cost for different grades of RM
Alloyin Typical
g cost INR/kg Cost breakdown
Grade 100%
6%
5% 16%
19%
Carbon
55 48%
steel 6%
Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
100%
7%
18%
16% 5%
Copper
80 8% 45%
steel
Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
100%
7%
19%
15% 5%
Nickel 110 42%
12%
steel
Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
100%
11% 6%
5%
25%
Pre
alloyed 15% 38%
steel 130
Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
Conversion cost for different grades of RM
Alloyin Typical
g cost INR/kg Cost breakdown
Grade 100%
10% 5%
5%
Low 25%
alloy 150 20% 35%

steel Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
100%
10% 5%
0%
25%
Sinter
Hardene 170 30% 30%
d steel
Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
100%
12% 6%
5%
Diffusion 25%
27% 25%
alloyed
steel 180
Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
100%
8% 5%
12% 5%
Copper 47% 23%
infiltrate
d steel
200 Raw Material Conversion Machining Heat Finishing Logistics/ Total cost
process Treatment process Packing
Sintering Technology

Powder Metallurgy
Process Overview
Cost overview
Basic Design Rules
References
Design rules to be followed while designing a sintered part
▪ Smaller radius minimum of
0.5mm at component corners
1.5mm min for both internal and external Chamfer &
wall thickness can be advantageous to tool lands
life.
▪ Very large radius will lead to
Add smooth density difference issues that
▪ Components of extremely ▪ At all edges, chamfer angle
radii lead to crack in compaction.
complicated shape in which wall ranging from 30° to 45° is
thickness varies over a very wide recommended.
range is more advantageous in this
1 ▪ This chamfer must be followed by
process. a land of 0.2mm to 0.5mm to
▪ The recommended minimum wall avoid protrusion of sharp edges.
6 2 ▪ These will help to improve the tool
thickness is 1.5mm.
Design for life.

Sintered
products
Add draft angle Tolerances
5 3

▪ Draft angles are provided for easier 4 ▪ Tolerances must be decided based
withdrawal of top punch after on the following factors,
▪ Through holes with minimum
compaction process. – Product dimensions
of 1.5mm diameter can be
▪ Draft angles may be minimized to considered in compaction.
– Load factors
as low as 2°. ▪ Blind holes less than 6.5mm
– Application
diameter are – Cost factors (Eg: Eliminating
recommended. It can be later
not machining process)
Hole Diameter
formed through drilling for better
tool life..
Sintering Technology

Powder Metallurgy
Process Overview
Cost overview
Basic Design Rules
References
Key sources – Further reading

1 www.ames-sintering.com

2 https://www.hoganas.com/en/

3 https://nptel.ac.in/courses/112107144/10

4 MAGAZINE-PMR-Summer-2017-PDF-single-page-edition

5 Hoganas Handbook Volume 1, 2 and 3.