POWDER METALLURGICAL

FILTERS
(POROUS MATERIAL)

Prepared By: Submitted to:

Aakash U. Desai
Roll no: 364 (Industrial Metallurgy)
Dr. V. J. Rao
Associate professor
Metallurgical and materials engineering Dpt.,
The faculty of technology and engineering,
The Maharaja Sayajirao University, Vadodara
 CONTENT

• Introduction
• Porous filters
• Production methods
• Testing codes
• Applications
• References
INTRODUCTION
• Porous components like bearings, filters and porous electrodes form
one of the major areas of application for P/M parts. These parts are
used for a wide range of individual applications.
• Porous materials are typical P/M products, which have controlled
amount of interconnected porosity in-built into the component for
specific applications. These engineered components are unique to P/M
and are difficult to produce by other techniques.
• Porosity usually expressed as a percentage and is obtained by
subtracting the density (%) of the material from 100.
• Closed porosity refers to the amount of isolated or closed pores within
the material. These pores do not serve any useful purpose and must be
minimized.
• Interconnected porosity refers to that fraction of porosity, which are
connected with one another and to the external surface.
 POWDER METALLURGICAL POROUS
FILTERS

• Porous filters are important porous P/M products with a controlled level of
porosity to aid in important industrial processes like filtration and flow control.
• Porous filter parts made by P/M routes can be classified into four major types
based on their application namely filtration, flow control, distribution and
porosity.
• Filtration is a separation process involving the removal of a gas, liquid or solid
from another gas or liquid.
• Flow control involves the regulation of fluid flow in a system with controlled
pressure drop.
• Distribution involves providing a uniform fluid flow over a wide area, as in a
sparger or in an air-bearing.
PRODUCTION METHODS
• Porous P/M filters can be made by a variety of techniques, depending
on the base material, level of porosity required, size as well as the shape
complexity of the part.
• Major techniques used for porous P/M filters production are gravity
sintering, powder rolling, powder rolling, powder spraying and die
compaction followed by sintering.

Sintering
in a
mould
Porous
Mixing (non-
Filter
oxidizing
atmosphe
re)
GRAVITY SINTERING
POWDER ROLLING
DIE COMPACTION AND SINTERING
SECONDARY OPERATIONS ON
POROUS PARTS
 SECONDARY OPERATIONS

• Machining
• Press fitting and sinter bonding
• Joining
• Insert bonding
• Cleaning
TESTING
 TESTING OF POROUS SINTERED MATERIALS

• Sintered porous components are normally checked for their dimensions

as well as type and level of porosity.
• Other tests done on porous parts are application-related and are aimed
at testing the satisfactory performance of the part under specified
conditions.
• Performance tests are carried out under simulated conditions and
important functional parameters such as flow rate and pressure drop are
measured.
• The manufacturer and the user usually establish such performance test
procedures jointly. The design of test fixtures as well as their calibration
is also done likewise.
Some of the International Standards developed for testing permeable
sintered metal materials are:
o ISO 2738-Determination of density, oil content and open porosity.
o ISO 4003-Determination of bubble test pore size (maximum pore size).
o ISO 4022-Determination of fluid permeability.
o ASTM E128-Standard test method for maximum pore diameter.
Some of the design capabilities and limitations of the different
production methods are as follows:
• Gravity sintering can produce very small size to very large parts whose
dimensions are dependent on furnace chamber size. The process enjoys
advantages like low-cost tooling, ability to produce parts with undercuts and
tapered parts. Shrinkage is a disadvantage and suitable allowance must be
provided to take care of shrinkage.
• In die compaction and sintering, part size ranging from under 0.02" in
diameter to 12" diameter can be made, design being limited only by press
capacity and furnace size. Length/diameter ratio should be kept below 2.5:1.
Close dimensional tolerances are possible.
• In isostatic compaction and sintering, long slender part with high-aspect
ratio are possible. Part sizes from 1/8" up to 72" are possible by combining
with butt welding of shorter sections. Very close dimensional tolerances are
also possible.
• Chamfered edges can be readily added to porous parts with little or no
additional cost. This design feature enables easier assembly in press-fit
operations and strengthens the edges in high porosity, coarse-grained
parts. In the case of loose (gravity) sintered parts, only one edge may be
chamfered, though both top and bottom edges may be chamfered for
parts made by pressing.
• Other aspects of design include number of parts required and the need
for mounting of parts.
APPLICATIONS
POROUS METALLIC FILTERS
FLOW CONTROL
DISTRIBUTION
 REFERENCES

1. P. C. Angelo and R. Subramanian, “Powder Metallurgy Products” in

Powder Metallurgy: Science, Technology and Application, 2nd ed.,
New Delhi, India: PHI, 2009, Ch. 9, pp. 190-196.
2. B. K. Datta, “Applications of Powder Metallurgy” in Powder
Metallurgy: An advanced technique of processing engineering
materials, Eastern Economy Edition, New Delhi, India: PHI, 2012,
Ch. 4, pp. 140-143.
ANY QUERY!
THANK YOU…