Powder Metallurgy

Powder Metallurgy
• Process by which fine powdered materials
are blended, pressed into a desired shape,
and then heated to bond surfaces
• Little material waste and unusual mixtures
can be utilized
• Used for parts in the automotive industry,
household appliances, and recreational
equipment
 The Basic Process
Additives
Elemental or alloy
(lubricants or
metal powders
• Four basic steps binders)

1. Powder manufacture
2. Mixing or blending Blending
3. Compacting
4. Sintering Compaction

Sintering

Optional secondary Optional

manufacturing secondary finishing

Finished P/M
product
Factors to Consider in P/M

Type and size of powder

Amount and type of lubricant

Pressing pressure
Sintering temperature and time

Finishing treatments
(1) POWDER MANUFACTURE
 Powder Manufacture
• Properties of powder metallurgy products are
highly dependent on the characteristics of
starting powders

• Some important properties and characteristics:

Chemistry and purity
Particle size
Size distribution
Particle shape
Surface texture
 Powder Manufacture
• The majority of commercial powder is
produced by atomization
Atomization is a process where liquid metal is fragmented
into small droplets that cool and solidify into particles
Powder Manufacture
 Additional Methods of Powder
Manufacture
• Methods
Chemical reduction of particulate compounds
Electrolytic deposition
Pulverization or grinding
Thermal decomposition of particulate hydrides
Precipitation from solution
Condensation of metal vapors
• Almost any metal or alloy can be converted
into powder
Powder Testing and Evaluation
• Apparent density
 measure of a powder’s ability to fill available space
without external pressure
• Flow rate
 measures the ease with which powder can be fed
and distributed into a die
• Compressibility
 Measure of the effectiveness of applied pressure
• Green strength
 describe the strength of the pressed powder after
compacting
(2) BLENDING
 Blending
• Powder and a
combination of other
elements and additives
are blended together
into a fully
homogeneous mixture.
• Each blend is tailored to
meet the exact physical
requirements of the
finished component.
(3) POWDER COMPACTING
 Powder Compacting
 Process of compacting metal powder in a die
through the application of high pressures. 

 The compacted component is said to be in the

"green" state.
 Powder Compacting
• Most compacting is
done with
mechanical presses
and rigid tools

• Hydraulic and
pneumatic presses
are also used
 Compaction Sequence
• Two opposing force is created from a
combination of
resistance by the bottom punch
friction between the particles and die
surface
Compaction Sequence
 Additional Considerations During
Compacting
• When the pressure is applied by only one punch, the
maximum density occurs right below the punch
surface and decreases away from the punch
• For complex shapes, multiple punches should be used.
(4) SINTERING
 Sintering
• Process wherein the pressed-powder compacts are
heated in a controlled atmosphere to right below the
melting point

• Three stages of sintering

 Burn-off (purge)
 High-temperature
 Cooling period
 Sintering

BURN-OFF HIGH-
COOLING PERIOD
(PURGE) TEMPERATURE

combusts any air desired solid-state lowers the

and removes diffusion and temperature of the
lubricants or binders bonding occurs products in a
that would interfere controlled
with good bonding atmosphere
 Hot Isostatic Pressing
• Process used to reduce the porosity
of metals and influence the density of
many materials.
• The HIP process subjects a component to
both elevated temperature and isostatic gas
pressure in a high pressure containment
vessel.
Hot Isostatic Pressing
Metal Injection Molding (MIM)
Metal Injection Molding (MIM)
 Secondary Operations
• Enhance precision

• Improve properties

• Produce special characteristics

• Correct/remove distortion
 Secondary Operations
• P/M forging
– Increases density and adds precision
• Infiltration and impregnation
– gives the part self lubricating properties and improves
strength
• Heat treatment
– increase strength and also hardness for improved wear
resistance
• Machining
• Surface treatments
 Advantages and Disadvantages of P/M
• Advantages
– Elimination or reduction of
machining
– High production rates
– Wide variations in
compositions
– Wide property variations
– Scrap is eliminated or
reduced
• Disadvantages
– High tooling costs
– High material cost
– Size and shape limitations
– Dimensional changes during
sintering
– Density variations
QUIZ
 The Basic Process
Additives
Elemental or alloy
(lubricants or
metal powders
• Four basic steps binders)

1. Powder manufacture
2. _____________ 1
3. _____________
4. _____________ 2

Optional secondary Optional

manufacturing secondary finishing

Finished P/M
product
 Question # 4

• Process of producing
commercial powder.
 Question # 5

• Describes the strength of

the pressed powder after
compacting.
 Question # 6

• Process that subjects a

component to both elevated
temperature and isostatic gas
pressure in a high pressure
containment vessel.
 Question # 7-9

• Three stages of sintering

Question # 10