Powder Metallurgy

OBJECTIVES

(1) Overview of powder metallurgy (PM) process.

(2) Demonstration of the process, with compaction of
copper powder in a cylindrical die-punch setup.
(3) Study of the effect of compacting pressure on the
green density of compact.
 Powder Metallurgy
Powder metallurgy, or PM, is a process of forming parts by compacting
metallic powders in to desired shapes and sizes and heating the compacted
parts (green parts) to well below their melting points (sintering temperature).
Steps 1 2 3 4
Sizing of
Powders Blending Compaction Sintering
powders
Powder Metallurgy Steps
Additional processes in powder metallurgy (optional)
 Sizing of Powders (Ball Milling)
In this step, the particle size is reduced using ball milling process. It is a
process where the powders are placed in a jar (vail) contain balls and these jars
are rotated at very high speeds. The powder particles are fractured due to high
energy impact with the balls. The jars and the jars are preferred to be of the
same material as the powder material.

(a) Planetary ball mill; (b) Schematic depicting the ball motion inside the ball mill.
Blending (mixing) of Powders

(a) - (d) Some common bowl geometries for

mixing or blending powders

(e) Powder mixer

e
 Compaction of Powders
Powder are compacted to different shapes using dies and punches of various configurations
( uniaxial compaction ) and flexible rubber molds (isostatic compaction) under high pressure.

Isostatic Compaction
Uniaxial Compaction

• Compaction Pressure effects the density of the compacted powder

• Particle size effects density, smaller particles results dense parts which
provides higher strength to the parts.
 Compacting Pressure Vs. Part Density, Strength

Effect of compaction pressure on microstructure Effect particle size of the initial powders on strength
 Density Definitions
True density (also called True particle density): The mass of a particle
divided by its volume, excluding pores with in the particle

Apparent particle density: The mass of a particle divided by its apparent

(particle) volume of the particle that includes open pores and closed
pores with in the particle

Apparent powder density or Bulk powder density or Bulk density of

Solids : The mass of the powder (or solid) divided by the volume they
occupy that includes the pores within the particles, and the pores (voids,
space) between the particles in a solid.
 Sintering Mechanism
Sintering is a process where compacted powder samples are heated to a
temperature up to 0.3 to 0.5 Tm, resulting in bonding between adjacent particles
to form bulk solids. Bonding occurs due to complex mechanisms but mainly due to
diffusion but there could be other mechanisms depending on the powders and
sintering conditions.
Sintering can be done under atmosphere air or vacuum and or specialized gas flow.

Bonding Mechanisms
Sintering Cycle
 Sintering Stages
First Stage: Preheating
Temperature is increased in order to remove volatile matter in the form of gas.
This increase in temperature should be done gradually as rapid heating could
entrap gasses and produce internal pressures that can fracture the green compact.

Second stage: Sintering

Temperature is held constant in order to induce solid-state bonding of particles by
diffusion (transport of metal atoms). As diffusion is time dependent, sintering
should be done for sufficient time (sintering time).

Third Stage: Cooling

Sintered product is cooled in a controlled atmosphere ( to prevent oxidation ) and
at moderate cooling rate ( to prevent thermal shock)
Sintering Time and Temperature for Metals
 Powder Metallurgy Products
Powder metallurgy products are generally the products which cannot be
machined because of high hardness or cannot be casted because of high
melting point.
 Powder Metallurgy Products
Porous Parts Impregnation of Oil in Porous Parts

Range of particle sizes

Filters
Self lubricating bearings
 Advantages of Powder Metallurgy Processing

1. Virtually unlimited choice of materials.

2. Manufacturing of complex shapes.
3. Economical for mass production.
4. Close control of dimensions.
5. Very good material utilization – minimal loss of material.
6. Very good surface finish of parts.
7. Good repeatability of parts.

Limitations of Powder Metallurgy Processing

1. Limited part size and weight
2. Initial Investment cost high
3. High cost of powder material.
4. High cost of tooling.
Lab Experiment
 Lab Experiment
Powder Compaction: Data Table
Material of Metallic powder, Pure copper
Mass of the metallic powder, m= g
Apparent density of metallic powder, ρ= 3.46 g/cm3
Diameter of the compact, D= mm
Gap distance between the platen, hg = mm
m
Height of upper punch, hu = m
m
Height of lower punch, hl = m
m
initial height of Billet ho= hg - (hu + hl)= m
m
X-sectional Area of Billet = m2
m
Height of Billet m

Sr F ∆h F P h V ρ ρc
# (Lbs-f) (mm) (N) (Mpa) (mm) (mm3) (g/mm3) (g/cm3)
1 0 0 0
2