A Seminar on

Advanced Technology in Powder Metallurgy

Advanced Technology in Powder

Metallurgy
Introduction
Process
Effect of density on various mechanical
properties.
Advanced Technology
Applications
Advantages
Limitations
Conclusion
References

Powder Metallurgy
Powder metallurgy is a branch of
metallurgy which deals with the
production of metal and non metal
powders
and
subsequently
manufacture of components by
using these powders.

Flowchart of Powder Metallurgy Process.

Producing metal powders of suitable size, shape and purity.

Blending and mixing of powders

Compacting

Presintering

Sintering

1) Production of Metal Powders

Methods
1.
2.
3.
4.
5.
6.

Atomization
Reduction
Electrolysis
Crushing
Milling
Condensation of metal vapours

Range of particle sizes

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Automisation

Automisation

Automisation
A high pressure steam or liquid
impinges on the molten metal which is
passed through orifice causing it to
automise into fine particles.
Sometimes inert gas is used to get pure
powder.
High quality powders of Aluminum,
brass, iron, stainless steel, tool steel,
super alloys are produced commercially

Reduction
The compound of metals are reduced with
CO and H2 gas in controlled atmosphere
The reduced product is crushed and ground
to get metal powder.
e. a. Tungsten oxide Tungsten powder
Iron Chloride Iron powder
Metal powders obtained Copper, Iron,
Tungsten, Molybdenum, Nickel.
Very convenient, economical, and flexible
method, so it is widely used.

Electrolysis
The process is similar to
electroplating
In this process anode and cathode
are placed in the electrolyte bath.
High intensity current detoriates
anode and cathode is deposited by
pure copper powder.
The cathode plates are taken out and
scraped off to collect copper powder.

Electrolysis

Electrolysis
Iron Powder
Copper Powder

Crushing
Totally mechanical process.
Brittle metal or alloy can be easily
crushed.
It requires crushing machinery like
stamps, hammers, jaw crusher etc.

Crushing Process

Jaw Crusher
Crusher

Gyratory Crusher

Roll

Milling
This is also mechanical process.
Used whenever large amount of powder is to be
produced.
Used for hard, soft, ductile or brittle materials.
It requires ball mill, impact mill, eddy mill, or
vortex mill.
A ball mill is widely used which is horizontal
barrel shaped container holding number of balls
which being free to tumble about as the
container rotates.
Then crush or grind to get fine powder.

Milling
This contains cylindrical vessel rotating horizontally
along the axis. Length of the cylinder is more or less
equal
to diameter. The vessel is charged with the grinding
media. The grinding media may be made of hardened
steel, or tungsten carbide, ceramics like agate,
porcelain,
alumina, zirconia. During rolling of vessel, the grinding
media & powder particles roll from some height. This
process grinds the powder materials by impact /
collision & attrition.

Milling process
Ball Mill
Attrition Mill

Rod Mill
Planetary Mill

Vibratory Ball Mill

Hammer Mill

Condensation
Used for metal powder like Zinc,
Cadmium, Magnesium.
In this process the metal can be
boiled and the vapours of the molten
metals are condensed to give metal
powder.
Used only for small scale production.

2) Blending & mixing of

Powders
Different powders along with lubricant mixed in a ball
mill. Lubricants are added to reduce friction during the
pressing operations. This reduces die wear and lowers
the pressure required for pressing.
After mixing the required properties like heat
resistance, friction, weight and hardness can be
obtained.
Blending types
Dry method
Wet method: Liquid medium like alcohol, acetone, benzene or
distilled water are in wet milling.
Advantages of wet mixing 1) Reduces dust. 2) Avoids
explosion hazards, 3) Prevents surface oxidation.

3) Compacting
Compacting means pressing the powders
into their semi-finished form of desired
shape.
Powders are compacted by using high
pressure.
Compacting methods
1) Die pressing
2) Roll pressing
3) Extrusion

Die pressing

Roll compacting

Extrusion

Presintering
When some machining is required
then
presintering
operation
is
employed before sintering operation.
For presintering the compacted parts
are heated for a short time at a
temperature considerably below the
sintering temperature.

Sintering
Sintering is done to get required strength
and hardeness in the finished product.
Sintering consists of heating a compacted
parts in a furnace to a temperature below
melting point of the major constituent in a
controlled atmosphere.
Sintering is process of bonding solid bodies
by atomic forces.
Sintering gives required shape to the
component.

Secondary operations
In many cases, the powdered
products may be used as sintered
condition, but in other cases where
desired surface finish, tolerance, or
metal structure can be obtained by
certain additional secondary
operations.
1. Sizing
2. Coining
3.
Machining
4. Impregnation 5. Infiltration 6.

1. Sizing
Sintering process produces some
distortions and alteration in size.
To make it dimensionally correct,
place in die and repressed.
Sizing improves surface finish also.
A slight change in density occurs
after sizing operation.

2. Coining
The sintered part is repressed in the
die to reduce the void space and
impart required density.

3. Machining
Features as thread, under cuts,
grooves etc are not obtained after
sintering process.
Such machining is done after
presintered operations.
Boring, turning, drilling, tapping etc
can be done on the presintered parts
using tungsten carbide tools.

4. Impregnation
Sintered porous parts may be
impregnated with oil, grease or wax
to give self lubrication properties.
Sintered parts may be impregnated
with plastic also.
Improves corrosion resistance
Improves machinability.
Introduce pressure tightness.

5. Infilteration
A part is first pressed and sintered from
iron powder which gives 77 % density.
Then a replica(infiltrant) of copper is
placed over the part.
It is heated in furnace.
The infiltrant melts and enters in
porous parts gives 100% density.
Advantage - It increases strength, hardness
and density.

7. Heat Treatment
Sintered parts are heat treated to improve
Wear resistance
Grain structure
Hardness
Strength

Heat treatment processess

Stress relieving, Carburising, Carbonitriding,
Nitriding, Through hardening, Induction
hardening,
Precipitation hardening.

6. Plating

Cr Plating Impart pleasing appearance

Ni plating Protect from corrosion resistance.
Sn plating Improves frictional characteristics.
Cu and Ag plating Improves electrical
conductivity.

Note: Before plating the parts are impregnated

with plastic, so electrolyte is not entrapped in
porous structure.

Effect of Density on Ductility and

Toughness of Fe-N P/M alloy

Effect of Density on Strength

of Fe-N P/M alloy

Advanced Technology in Powder

Metallurgy
1. Improvement in for mechanical properties.
a. By Increasing powder compressibility/homogeneity,
dust and hazard reduction.
. Better particle size distribution.
. Atomisation nozzle geometry
. High-pressure water atomization
. Vacuum induction melting, degassing and pouring
furnaces to replace the common ones.
. To enhance the sintered steels homogeneity and to
reduce dust, the traditional elemental powder
mixtures are being replaced, in spite of their lowest
cost.

Advanced Applications for Metal

Powders
Application

Metals

Uses

Abrasives

Fe, Sn, Zn

Cleaning, abrasive wheels

Aerospace

Al, Be, Nb

Jet engines, heat shields

Automotive

Cu, Fe, W

Valve inserts, bushings, gears

Electrical/electronic

Ag, Au, Mo

Contacts, diode heat sinks

Heat treating

Mo, Pt, W

Furnace elements,
thermocouples

Joining

Cu, Fe, Sn

Solders, electrodes

Lubrication

Cu, Fe, Zn

Greases, abradable seals

Magnetic

Co, Fe, Ni

Relays, magnets

Manufacturing

Cu, Mn, W

Dies, tools, bearings

Medical/dental

Ag, Au, W

Implants, amalgams

Metallurgical

Al Ce Si

Metal recovery, alloying

Nuclear

Be, Ni, W

Shielding, filters, reflectors

Office equipment

Al, Fe, Ti

Electrostatic copiers, cams

Advanced Technology in Powder

Metallurgy
b. Improving the die filling and lubrication
processes.
A high filling density and uniformity over the
cross section of the die cavity is essential for
good quality parts obtaining.
Use of agitating feed-shoes or vibratory feeders.
Use organic binder.
A good lubrication during compaction plays a
major role in obtaining a high and uniform
density.

Advanced Technology in Powder

Metallurgy

c. Advanced compaction methods

Warm compaction up to 1500 C allowing a
higher densification at the same applied
pressure.
High velocity compaction leading to higher
density by a hydraulically - operated
hammer.

Advanced Technology in Powder

Metallurgy

d. High Temperature Sintering

Higher densification.
Better homogenization
Fatigue resistance and toughness being
improved.
But it leads to the crystal grain growth
and higher cost.

Advanced Technology in Powder

Metallurgy
2. Extending PM capability of complex parts
processing.
a. Powder Injection Molding.
Powder Injection Molding (PIM) combines the polymer injection
technology with powder metallurgy. By injection of a powderbinder mixture (feedstock) in a die cavity, theoretically any
shape can be realized.

a. Selective Laser Sintering.

In each layer and between two successive layers, a laser
beam, by a computer controlled sequential displacement in
coordinates, joints particles upon a program to realize the
required cross section of the part for that layer. The process is
repeated until the whole part is built, layer-by-layer.

Applications of Powder
Metallurgy
1.
2.
3.
4.
5.
6.
7.

Porous products porous bearings, filters

Electrical contacts in automobile industry
Crankshaft drive, camshaft sprocket
Piston rings, brake liners, connecting rods.
Door mechanism.
Sintered gears (Without much manufacturing)
Refractory parts - e.a. Tungsten in electric
bulb, filament in X ray tube, cathode,
anode, control grid.

Applications of powder
metallurgy
8. Wire drawing dies, wire guides, deep drawing,
stamping, blanking tools, rock drilling bits (made
of tungsten carbide)
9. Non porous bearings, electric motor brushes.
10.Military and defense applications in rockets,
missiles, cartridge cases, bullets etc.
11.Atomic energy applications in various fuel
system, control rod systems and radiation
reflectors.
12.Parts in clocks, timing devices, typewriters,
calculators, permanent magnets.

Cermet cutting inserts for lathe

Powder Metallurgy:

Cermet cutting tools

(Ceramic-Metal composite)

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Microstructure: ceramic particles in metal matrix

Cermet-tipped saw blade for long life

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Slightly porous appearance

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P/M net-shape gears are common, save machining time

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Metal filters
Powder Metallurgy:
Porous Metals

Oil-impregnated Porous Bronze Bearings

nic.sav.sk

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Powder Metallurgy: Connecting Rods

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Forged on left; P/M on right

Powdered Metal Transmission Gear

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Warm compaction method with 1650-ton press

Teeth are molded net shape: No machining
UTS = 155,000 psi
30% cost savings over the original forged part

Powdered Metal Turbine blade-disk (blisk): 1 piece!

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Conventional Forging vs. Forging of Powdered Metal blank (2nd op)

DeGarmo

P/M Tungsten Lightbulb Filament:

500 hrs at 2500C
Wire is creep resistant, note facets on close-up are evaporated W.

Advantages of Powder
Metallurgy
1.
2.
3.
4.
5.
6.
7.
8.

Machining is not required.

Dimensional accuracy and surface finish.
More cleaner and quieter applications
High production rates.
No wastage.
Complex shape can be produced.
Longer life of components.
Excellent reproducibility.

Advantages of Powder
Metallurgy
9. P/M is only method to produce porous
products.
10.Skilled worker is not required.
11.Impossible parts like tungsten carbide can
be produced by P/M process.
12.Use of diamond in industry is due to P.M only.
13.No need to study phase diagram.

Limitations of Powder
1. High ProductionMetallurgy
Cost .
2.
3.
4.
5.

High Tooling Cost.

Complicated products can not be produced.
Poor Physical properties.
Large sized products can not be produced due to
requirement of large presses.
6. Extreme care should be taken in handling pyrophoric
(Fire Explosive) powders like Mg, Th, Zr
7. Toxic powders like U, Be, Th should be handled
carefully.
8. Not economical for small scale production.
9. Can not obtained any specific alloy.
10.Density may vary.

Conclusion
The powder metallurgy product can
be improved
By improving mechanical and physical
properties like ductility, toughness,
strength, homogeneity etc.
By
using
modern
manufacturing
techniques like injection mounding,
Selective Laser Sintering etc.

References
Material Science & Metallurgy by O. P.
Khanna
Material Science & Metallurgy by Dr. V. D.
Kodgire
DeGarmo: E.P. DeGarmo et al, Materials and
Processes in Manufacturing, Wiley, 2003.
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uestions Please

Thank You