POWDER

METALLURG
Y

TEAM MEMBERS:

VIDHIDUHITA RAUL
(111021008)

GAYATRI VORA
(111021024)

DEVASHRI VAGHOLKAR
(111021037)
 2 11/27/2021

INTRODUCTION

 Powder metallurgy is the process of blending fine

powdered materials, pressing them into a desired
shape or form, and then heating the compressed
material in a controlled atmosphere to bond the
material.

 Basicallya chipless metalworking process, P/M

typically uses more than 97% of the starting raw
material in the finished part and hence it is an energy
and materials conserving process. POWDER METALLURGY
 3 11/27/2021

PROCESS
1 Characterization
●
●

2 Powder Production
●
●

3 Mixing - Blending
●
●

4 Processing - Compacting
●
●

5 Sintering Operation
●
●

6 Finishing Operation
●
●
POWDER METALLURGY
 4 11/27/2021

A. CHARACTERIZATION AND
TESTING OF POWDERS
 Obtaining desired properties in a component depends on the
properties of metal powders used and hence it is essential to
test the powders.

 Ithelps in the selection of the right type of powder for a

given application.

POWDER METALLURGY
 5 11/27/2021

1. Chemical 2.Shape, Size 3. Particle

Composition and Porosity and
and Impurity Distribution Microstructure

4. Specific 6. Flow
Surface 5.Density Rate
7. Compacting
8. Sintering
or Pressing
Characteristics
Properties

POWDER METALLURGY
 6 11/27/2021

1. Chemical Composition and Impurity

 Impurities not only affect the component properties but also
influence the pressing and sintering characteristics and
hence its determination is very important.

 It can be determined by several standard techniques like :

a) Gravimetric Analysis
b) Volumetric Analysis
c) Colourometric Analysis
d) Spectroscopy
POWDER METALLURGY
 7 11/27/2021

2.Shape, Size and Distribution

It can be measured by the following methods:

1. Sieve Method : It is the simplest method in which sieves of different

mesh numbers are used.

2. Microscopic Method : Optical (2,000 x) and Electron (5,00,000 x)

Microscopes are used.

3. Sedimentation Method : Classification is based on the settling velocities

of powders in a fluid.

4. Elutriation Method : The metal powder is allowed to settle in a moving

liquid or gas of a constant velocity to determine size distribution of fine
particles.
POWDER METALLURGY
 8 11/27/2021

3. Particle Porosity and Microstructure

It is determined by using microscopy by mounting the powders in a
suitable medium.

1. HOT MOUNTING : Powder + Bakelite

The medium is mounted, polished, etched, washed with water and
alcohol and dried using blast of hot air and then examined under
microscope.

2. COLD MOUNTING : Powder + Polymeric Liquid + Hardener

The medium is poured in a steel tube in which the liquid polymerizes
and becomes hard in 10-15 mins. Then it is polished, etched, washed
and examined.

POWDER METALLURGY
 9 11/27/2021

4. Specific Surface
 Total surface area of powder per unit weight (cm2/gm).

 The compacting and sintering properties are highly

dependent on the contact area.

 Methods of evaluation :
1. Permeability Method
2. Adsorption Method

POWDER METALLURGY
 10 11/27/2021

5.Density
1. APPARENT DENSITY :
 It is defined as the mass per unit volume of a loosely or unpacked powder.
 It includes internal pores only and strongly influences the pressing
characteristics.
 It is measured by using standard flow meter funnel or volumeter.

2. TAP DENSITY :
 It is the apparent density of the powder after it has been mechanically
shaken or tapped until the level of powder remains constant.
 It is measured by Ro tap machine.

POWDER METALLURGY
 11 11/27/2021

VOLUMETER

RO-TAP MACHINE

POWDER METALLURGY
 12 11/27/2021

6. Flow Rate
 It is defined as the rate at which metal powder will flow under gravity
from a container through an orifice having specific shape and size.
 It is measured by using a flow meter which is a conical brass funnel with
an internal angle of 60 ̊.
 It depends on :
 Size and shape
 Distribution
 Amount of adsorbed gases
 Moisture
 Coefficient of friction

POWDER METALLURGY
 13 11/27/2021

7. Compacting or Pressing Properties

It is represented in terms of :

 Compressibility :
Ability to undergo deformation under the applied
pressure.

 Compactibility :
The minimum pressure required to produce a compact.

POWDER METALLURGY
 14 11/27/2021

8. Sintering Characteristics
The sintering characteristics and quality can be determined by
testing the following properties :

 Dimensional Change i.e. % Shrinkage

 Density and Porosity
 Mechanical Properties
 Microstructure

POWDER METALLURGY
 15 11/27/2021

B. POWDER MANUFACTURING
 There are various ways to manufacture powder and each
method gives a power of different size, shape,
distribution and has different characteristics.
 Therefore, a right type of powder in the correct
proportion should be used for obtaining the desired
properties in the final sintered product.
 The proper choice of method depends on the type of raw
material, desired properties, final component and
economy of the process.
POWDER METALLURGY
 16 11/27/2021
MECHANICAL
PROCESSES
MECHANICAL

PHYSICAL
PROCESSES

PROCESSES
PHYSICAL
PROCESSES

POWDER
MANUFACTU
RING

PROCESSES
CHEMICAL
ELECTRO-
PROCESSES

PROCESSES
CHEMICAL
ELECTRO-
CHEMICAL
PROCESSES
CHEMICAL

POWDER METALLURGY
 17 11/27/2021

I. MECHANICAL PROCESSES
MACHINING

CRUSHING

MILLING

SHOTTING

GRAINING

AUTOMIZATION

POWDER METALLURGY
 18 11/27/2021

TYPES OF CRUSHERS

POWDER METALLURGY
 19 11/27/2021

MILLING

POWDER METALLURGY
 20 11/27/2021

SHOTTING GRAINING
Molten metal is poured on a vibrating screen and the
liquid droplets are solidified.

Solidification by air or Solidification by water

neutral gas

In both the methods powders contained are coarse

Other pulverization methods required.

POWDER METALLURGY
 21 11/27/2021

AUTOMIZATION

 Theprocess of metal spraying against a stream of

compressed air or inert gas is Atomization.

 Itis an excellent means of producing metal powders from

many of the low temperature metals such as lead,
aluminium, zinc and tin

POWDER METALLURGY
22 11/27/2021

POWDER METALLURGY
 23 11/27/2021

2. PHYSICAL PROCESSES

CONDENSATION

THERMAL DECOMPOSITION

POWDER METALLURGY
 24 11/27/2021

CONDENSATION
 Metal vapours condensed to obtain powder

 Highly suitable for volatile metals

 Powder shape is nearly spherical

POWDER METALLURGY
 25 11/27/2021

THERMAL DECOMPOSITION
 Thermal decomposition of carbonyl vapours.

Fe 5CO Fe(co)5

Solid metal vapours 200 to 270°

Carbonyl
70 to 200 atm

Fe(co) Fe 5CO
5

Carbonyl 150 to 400° Metal powder

1 atm POWDER METALLURGY
 26 11/27/2021

3. CHEMICAL PROCESSES

REDUCTION

INTERGRANULAR CORROSION

PRECIPITATION

POWDER METALLURGY
 27 11/27/2021

REDUCTION
 Metal compound is reduced by suitable reducing agent
to obtain metal powder.

 Example:
Chromium powder is produced by reduction of
chromium oxide with Mg.

 Powders obtained are fine.

 Shape of particles is irregular.

POWDER METALLURGY
 28 11/27/2021

INTERGRANULAR CORROSION
 Grain boundaries corrode faster than grains.

 Grainboundary area of metal under interest is corroded by a

suitable electrolyte so as to separate out grains from the
polycrystalline metal.

POWDER METALLURGY
 29 11/27/2021

PRECIPITATION FROM
AQUEOUS SOLUTION
 Lessnoble metal displaces more noble metal from an
aqueous solution containing ions of more noble metal.

 Example: Silver is displaced from a silver nitrate solution

by Cu or Fe.

 Excellent purity.

 Dendritic shape.
POWDER METALLURGY
 4. ELECTRO-CHEMICAL
30 11/27/2021

PROCESSES
 Powder obtained by electro deposition from aqueous
solution.

 Similar to electroplating.

 Conditions favorable for powder formation on cathode:

1. High current density
2. Low metal ion concentration
3. High acidity
4. Low temperature
POWDER METALLURGY
 31 11/27/2021

Types of Electrodeposition

Soft and spongy,

Hard and brittle, loosely adherent and Direct deposition as
which is subsequently fluffy texture which is powder in bottom of
ground to powder powdered by light the cell
rubbing

POWDER METALLURGY
 32 11/27/2021

C. POWDER BLENDING
 Powders of metals and non-metals are carefully blended to
obtain uniform mixture.
 This is essential for obtaining the desired properties.
 Lubricants are used to reduce friction between die walls
and the punches.
 Various types of blenders and mixers are available to suit
particular requirements of the components produced.
 For better mixing Tumbling action is necessary and
hence Y cone or Double cone Blender is used.

POWDER METALLURGY
 33 11/27/2021

Types of Blenders

POWDER METALLURGY
 34 11/27/2021

D. POWDER COMPACTING
 Powder compaction is the process of
compacting metal powder in a die
through the application of high
pressures.
 The tools are held in the vertical
orientation with the punch tool forming
the bottom of the cavity.
 The powder is then compacted into a
shape and then ejected from the die cavity.
 The density of the compacted powder is
directly proportional to the amount of
pressure applied which should be between
1 to 150 kg/mm.
POWDER METALLURGY
 35 11/27/2021

Compaction Cycle
1. Cycle Start
2. Charge die
3. Compaction begins
4. Compaction complete
5. Ejection of compact
6. Recharging of die

POWDER METALLURGY
36 11/27/2021

POWDER METALLURGY
 37 11/27/2021

Compacting Tools
 Toolingmust be designed so that it
will withstand the extreme pressure
without deforming or bending.
Materials used should be polished
and wear-resistant.
 There are 4 major classes of tools:
1. Single Action Compaction ( for thin, flat
components)
2. Opposed Double Action with Two Punch
Motions (which accommodates thicker
components)
3. Double Action with Floating Die
4. Double Action Withdrawal Die
POWDER METALLURGY
 38 11/27/2021

E. SINTERING
 Solid state sintering is the process of
taking metal in the form of a powder
and placing it into a mold or die.

 The material is placed under a high

heat (~80% of melting temperature)
for a long period of time.

 Under heat, bonding takes place

between the porous aggregate
particles and once cooled the powder
has bonded to form a solid piece.

POWDER METALLURGY
 39 11/27/2021

Sintering proceeds in three

stages.
1. Neck growth proceeds rapidly but
powder particles remain discrete.

2. Most densification occurs, the structure

recrystallizes and particles diffuse
into each other.

3. Isolated pores tend to become spheroid

and densification continues at a much
lower rate.

POWDER METALLURGY
 40 11/27/2021

POWDER METALLURGY
 41 11/27/2021

Types of Sintering
 Two types of sintering :-

 Solid Phase Sintering : The

compacts are heated above
recrystallization temperature of
low melting metal.

 Liquid Phase Sintering : The

compact is heated above the
melting point of one of the alloying
elements. Alloying may take place
at the interface of the particles.
POWDER METALLURGY
42 11/27/2021

POWDER METALLURGY
 43 11/27/2021

F. FINISHING
 Repressing:
Additional compacting operations, performed under
high pressure in presses (coining, sizing).

 Impregnation:
Utilizes inherent porosity of P/M components by
impregnating them with a fluid (oil).

 Infiltration:
A slug of lower melting point metal is placed against
the sintered part, the assembly is heated to melt slug. By
capillary action, the liquid slug fills the pores of the
sintered part. POWDER METALLURGY
 44 11/27/2021

ADVANTAGES
 Combinations of metals and non metals powdered parts can
be manufactured.

 High Dimensional accuracy.

 No material is wasted as scrap.

 Porous parts and cemented carbide tools can be produced

which is not possible by any other method.

POWDER METALLURGY
 45 11/27/2021

 Highly qualified or skilled person is not required.

 Large scale production is economical and gives efficient

results.

 Eliminates numerous machining operations.

 Powder metallurgy parts can be easily brazed, welded ,

soldered.

 Fine Surface finish is achieved.

POWDER METALLURGY
 46 11/27/2021
RECOGNISED GREEN
TECHNOLOGY
 In an initiative undertaken by the
Metal Powder Industries
Federation, the PM industry is
proclaiming to the manufacturing
community that powder metallurgy
is a recognized "green" technology.

 Being sustainable is a way of life

and—for many of us in the PM
industry—being green is now a way
of doing business.

POWDER METALLURGY
 47 11/27/2021

DISADVANTAGES
 High tooling costs and expensive raw materials.

 Difficult storing and handling of powders (degradation with time

and fire hazard with particular metallic powders).

 Not economical for small scale production.

 Products have poor ductility, purity of powder is low and they

show poor plastic properties.

 Porosity makes it difficult to obtain some mechanical properties.

POWDER METALLURGY
 HOT ISOSTATIC PRESSING
48 11/27/2021

(HIP)
 HotIsostatic Pressing of encapsulated powder metal
produces net or near net shape parts with special particle
properties.
 The process takes place well below the melting point of
the material, typically resulting in a very fine grained
structure.

POWDER METALLURGY
49 11/27/2021

POWDER METALLURGY
 50 11/27/2021

ADVANTAGES OF HIP PROCESS

Hot Isostatic Process P/M parts are:

 Isotropic
 Densification of powdered metal parts
 Elimination of porosity
 Improved mechanical properties
 Little or no secondary machining
 Decreased scrap loss

POWDER METALLURGY
51 11/27/2021

POWDER METALLURGY
 52 11/27/2021

APPLICATIONS
Powder Metallurgy finds wide applications in the industry
and several market segments offer potential growth areas
for powder metallurgy manufacturing techniques.

 Automotive components
 Aerospace
 High temperature applications
 Healthcare sector
 Defence

POWDER METALLURGY
 53 11/27/2021

Automotive Components
 Manufactureelectrical contacts, crank shaft, piston rings,
connecting rods, clutches, brakes, dynamos, etc.

 Titaniumis in exhaust systems using cheap commercially

pure (CP) sheet. Turbochargers, valves and springs are usually
made from titanium alloys.

 Used as a fabrication technique for automotive components,

with many cars containing up to 8-30 kilograms of parts made
this way.

POWDER METALLURGY
54 11/27/2021

POWDER METALLURGY
 55 11/27/2021

Aerospace
 Metal powders play an important role in rockets, missiles, satellites and
space vehicles.
 Metal powders of Be, Al, Mg and Zr are used as solid fuels in rockets and
missiles.
 Tungsten parts are used in plasma jet engines and ion engines operated at
about 1800 C.
 Net-shape HIP titanium Powder Metallurgy products have been
developed for turbine applications where conventional processing
(involving machining) is very wasteful of material and the Powder
Metallurgy route can offer cost benefits.

 Airframe sector:
There is also growing interest in the use of titanium Powder Metallurgy
in the airframe sector.
POWDER METALLURGY
56 11/27/2021

POWDER METALLURGY
 57 11/27/2021

High Temperature Applications

 Components made of W, Mo and Ta by powder metallurgy
are widely used in electric light bulbs, fluorescent bulbs, radio
valves, mercury arc rectifiers and X ray tubes in the form of
filament,etc.

 Refractory metal carbides are used for dies, rolls, cutting

tools, etc. at high temperatures.

 Production of super alloys is also possible by powder

metallurgy.

POWDER METALLURGY
58 11/27/2021

POWDER METALLURGY
 59 11/27/2021

Healthcare Sector
 Titanium and titanium alloys are ideally suited to medical
implants because titanium is biocompatible and inert to
human body fluids.
 MRI scanners used large quantities of rare earth permanent
magnets, processed from powders.
 Surgical instruments and dental implants are produced.
 Customized medical implants using additive manufacturing
and in producing porous implant structures (to match bone
stiffness and to aid osteo-integration) by PM processing.

POWDER METALLURGY
60 11/27/2021

POWDER METALLURGY
 61 11/27/2021

Defense Applications
 Metalpowders play an important role in military and national
defense systems.

 They find use in missiles, rockets, cartridge cases, bullets,

etc.

 Also used in military pyrotechnics like tracers, incendiaries,

etc.

POWDER METALLURGY
 62 11/27/2021

Powder Metallurgy Products

Oil-impregnated Porous Bronze Bearings Connecting Rods

Gears

POWDER METALLURGY
 63 11/27/2021

1. Self Lubricating Bearings

 Self-lubricating oil-impregnated PM bearings find their applications in
mechanical and electromechanical devices, where sliding processes,
especially rotary motions, are occurring. 
 Friction and wear are reduced, and liquids can carry away both
frictional heat and wear debris generated during the sliding process.
 When the shaft is at rest all the oil is retained in the pores and the load is
sustained by direct metallic contact between the two surfaces. At the
beginning of movement the direct metallic rubbing between bearing and
journal with its high friction coefficient raises the temperature rapidly.

POWDER METALLURGY
 64 11/27/2021

2. Cermets
 Cermet is "a heterogeneous combination of metals or alloys with one or
more ceramic phases in which the latter constitutes approximately 15
to 85% by volume and in which there is relatively little solubility
between metallic and ceramic phases at the preparation temperature".

 Cermets originally were used for cutting tool applications.

 Refractory behavior, strength, and corrosion resistance of the ceramic

with the high ductility and thermal conductivity of the metallic phase
are some properties.

POWDER METALLURGY
 66 11/27/2021

3. Cemented Carbides And Cemented

Carbide Tipped Tools
 Tungsten carbide (WC), also referred to as
cemented carbide, is a composite material.
Tungsten carbide powder, generally ranging in
proportion between 70%-97% of the total
weight, is mixed with a binder metal, usually
cobalt or nickel, compacted in a die and then
sintered in a furnace.

 Carbides are brittle materials since it exhibits

little or no plastic deformation preceding the
initiation of a crack and total failure..

POWDER METALLURGY
 67 11/27/2021

 Withstand all forms of wear (including

sliding abrasion, erosion, corrosion/wear and
metal-to-metal galling) and exhibit a high
degree of toughness.

 It exhibits high compressive strength, resists

deflection, and retains its hardness values at
high temperatures, a physical property
especially useful in metal-cutting applications.

 It provides long life in applications where

other materials would not last or would fail
prematurely.

POWDER METALLURGY
68 11/27/2021

POWDER METALLURGY
 69 11/27/2021

THANK
YOU!

POWDER METALLURGY