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Why PM is important?
PM parts can be mass produced to net shape or near net shape, eliminating
or reducing the need for subsequent machining.
PM process wastes very little material - about 97% of the starting powders
are converted to product.
Why PM is important?
Automotive Components
Connecting Rods:
Forged on left; P/M on
right
Medical Applications
Advantages of PM
Components can be produced with good surface finish and close tolerance.
the product
Wide variation in composition
Scrap is eliminated or reduced
Disadvantages of PM
The metal powders and the equipment used are very costly
Parts manufactured by this process have poor ductility
Sintering of low melting point powders like lead, zinc, tin etc. offer serious
difficulties
Storing of powders offer great difficulties because of possibility of fire and
explosion hazards
Basic process of PM
Five basic steps
1. Powder manufacture
2. Mixing or blending
3. Compacting
4. Sintering
5. Finishing
Basic process of PM
Conventional powder metallurgy production sequence: (1) blending, (2) compacting, and
(3) sintering; (a) shows the condition of the particles while (b) shows the operation
and/or workpart during the sequence.
Particle size
Particle size distribution
Flow rate
Compressibility
Purity
Particle Shape
method
involves
the
for
producing
metal
In it steel plates are placed as anode and stainless steel plates are placed
as cathode
The two electrodes are connected to a powerful de source
In about 50 hours, a 2 mm thick deposit is obtained on the cathode
plates
possibly different particle sizes are intermingled. Different particle sizes are
often blended to reduce it to same size.
Mixing refers to powders of different chemistries being combined. An
advantage of PM technology is the opportunity to mix various metals into
alloys that would be difficult or impossible to produce by other means.
Compacting
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
The dies and punches used should be highly polished and the clearance
between them should be kept at the minimum in order to maintain proper
alignment.
Sintering
Heat treatment to bond the metallic particles, thereby
increasing strength and hardness.
Parts are heated to ~75-80% of melting temperature.
Sintering Sequence
Parts are heated to 0.7~0.8 Tm.
Transforms compacted mechanical bonds to much stronger
metallic bonds.
Powder Metallurgy
Sintering
Third stage:
Sintered product is cooled in a controlled atmosphere.
Prevents oxidation and thermal shock
Gases commonly used for sintering:
H2, N2, inert gases or vacuum
3/23/2015
Sintering
process
Some products may use secondary operation to provide enhanced
precision, improved properties, or special characteristics
Distortion may occur during non uniform cool- down so the product may
be repressed, coined, or sized to improve dimensional precision