Powder

Metallurgy
Presentation
by
K Ravi Kumar -ME
Introduction
• Powder metallurgy (PM) is a metal working
process for forming precision metal components
from metal powders. The metal powder is first
pressed into product shape at room temperature.
This is followed by heating (sintering) that causes
the powder particles to fuse together without
melting
Why Powder Processing ?

• The parts produced by PM have adequate physical and mechanical

properties while completely meeting the functional performance
characteristics.
• The cost of producing a component of given shape and the required
dimensional tolerances by PM is generally lower than the cost of casting or
making it as a wrought product, because of extremely low scrap and the fewer
processing steps.
• Parts can be produced which are impregnated with oil or plastic, or
infiltrated with lower melting point metal. They can be electroplated, heat
treated, and machined if necessary.
• The rate of production of parts is quite high, a few hundreds to
several thousands per hour.
Process in Powder Metallurgy
• Mixing (Blending)
• Compacting
• Sintering Atmospheric
vacuum

Cold sintering
compaction

Secondary and
Metal Powders Blending Hot finishing
compaction operations
Additives and
lubricants
Iso static Coining
pressing Forging
Machining
Production of • Widely used Metal Powders
Powders (Powder
Manufacturing)
Pure Metals Alloys

Aluminum Aluminum-iron
Antimony Brass
Beryllium Copper-zinc-nickel
Bismuth Nickel-chromium
Cadmium Nickel-chromium-iron
Cobalt Nickel-copper
Copper Nickel-iron
Iron Silicon-iron
Lead, Molybdenum Solder
Manganese, Zinc Stainless steel
 In general, producers of metallic
Production powders are not the same
of Metallic companies as those that make PM parts
Powders • Any metal can be made into powder form
• Three principal methods by which metallic
powders are

commercially produced

• Atomization (by gas, water, also centrifugal

one)
• Chemical
• Electrolytic
• In addition, mechanical methods are
occasionally used to reduce
Atomization:
• This method involves the conversion of molten metal into a spray of
droplets that solidify into powders.
• It is the most versatile and popular method for producing metal
powders today, applicable to almost
• all metals, alloys as well as pure metals.
 Blending and
Mixing of Powders
For successful results in compaction and sintering,
the starting powders must be homogenized
(powders should be blended and mixed).
Blending - powders of same chemistry but possibly
different
particle sizes are intermingled
 Different particle sizes are often blended to reduce
porosity
 Mixing - powders of different chemistries are
combined .
PM technology allows mixing various metals into
alloys that would
be difficult or impossible to produce by other means.
Blending or Mixing
 Blending a coarser fraction with a finer fraction ensures that the
interstices between large particles will be filled out.
Powders of different metals and other materials may be mixed in
order to impart special physical and mechanical properties
through metallic alloying.
Lubricants may be mixed to improve the powder’s flow
characteristics.
 Binders such as wax or thermoplastic polymers are added to
improve green strength.
Blending
To make a homogeneous mass with uniform distribution of
particle size and composition.
Powders made by different processes have different sizes and
shapes
Mixing powders of different metals/materials
Combining is generally carried out in
 Air or inert gases to avoid oxidation
Liquids for better mixing, elimination of dusts and reduced
explosion hazards
Compaction
Application of high pressure to the powders to form
them into the required shape.
Conventional compaction method is pressing, in which
opposing punches squeeze the powders contained in a die.
 The work part after pressing is called a green compact,
the word green meaning not yet fully processed.
The green strength of the part when pressed is adequate
for handling but far less than after sintering.
Compacting
 Press powder into the
desired shape and size in
dies using a
hydraulic or mechanical
press
Pressed powder is known
as “green compact”
 Stages of metal powder
compaction:
Compacting
Powders do not flow like liquid, they simply compress until an
equal and opposing force is created.
– This opposing force is created from a combination of
(1) resistance by the bottom punch and
(2) friction between the particles and die surface
Compacting consolidates and dandifies the component for
transportation to the sintering furnace.
Compacting consists of automatically feeding a controlled amount
of mixed powder into a precision die, after which it is compacted.
 Sintering
Heat treatment to bond the metallic particles, thereby increasing
strength and hardness.
Usually carried out at between 70% and 90% of the metal's melting
point (absolute scale)
 Generally agreed among researchers that the primary driving
force for sintering is reduction of surface energy
Part shrinkage occurs during sintering due to pore size
Reduction
 Parts are heated to ~80% of melting temperature.
 Transforms compacted mechanical bonds to much stronger metal
bonds.
 Many parts are done at this stage. Some will require additional
processing.
Powder Metallurgy Merits
Near Nett Shape is possible, thereby reducing the post-production
costs, therefore:
Precision parts can be produced
The production can be fully automated, therefore,
Mass production is possible
 Production rate is high
 Over-head costs are low
Break even point is not too large
Material loss is small
Advantages of P/M
Virtually unlimited choice of alloys, composites, and
associated properties
 Refractory materials are popular by this process
Can be very economical at large run sizes (100,000
parts)
Long term reliability through close control of
dimensions and physical properties
Wide latitude of shape and design
Very good material utilization
Limitations and Disadvantages
 High tooling and equipment costs.
 Metallic powders are expensive.
 Problems in storing and handling metal powders.
Degradation over time, fire hazards with certain metals
 Limitations on part geometry because metal powders do not
readily flow laterally in the die during pressing.
Variations in density throughout part may be a problem,
especially for complex geometries.