Powder processing - Applications

The iron pillar in Delh

(400 AD) i is the largest
historical piece
constructed using powder
metallurgy.
Fabricated out of solidstate reduced ferrous
granules by sinter-forging
technique.

Applications of PM products

Structural
Machine tool
Power generation
Friction
Electrical
Magnetic
Other
Thermal management
Bio-implants

Structural: Automotive Application

Engine ignition system, e.g., distribution gears
Oil and water pumps, e.g., gears, impellers
Gearbox/transmission, e.g., parts for gear-selection
mechanism, clutch hubs and other clutch parts
Steering system, e.g., rack and pinion mechanism parts
Suspension, e.g., shock absorber and struts parts
Braking system, e.g., disc pads supporters, pistons, ABS
sensors
Brake discs using particulate-reinforced aluminium matrix PM
composites containing silicon carbide

Structural: Aerospace Application

PM Ni-based superalloys are used in aerospace applications
Ceramic gas turbine stators, made of Si3N4 and SiC at the
development stage
Aircraft fasteners are generally made of PM Ti-6Al-4V alloys.
In satellite structural applications PM beryllium
Ion jet rockets porous tungsten
Rocket nozzle throat sintered tungsten
High-load, high-speed bearings Si3N4 ceramic bearing

Structural: Defence application

Heavy-alloy penetrators
Machine-gun parts, e.g., gears, guide fins for projectiles
Missile applications, e.g., nose cones, wings
PM metal matrix composites (Al-30% SiC) have been found
suitable for torpedo applications in navy
Armour ceramics Al2O3, B4C, SiC

Machine tools: Cutting applications

Cutting tools must have room temperature hardness,
resistance to thermal softening, toughness, stiffness, wear
resistance, resistance to chemical reaction, high thermal
conductivity, low thermal expansion, machinability and
grindability
Tool materials steels, non-ferrous alloys, cemented carbides,
cermets, ceramics and super-hard materials
Diamond tools impregnated with metal matrix is produced by
hot pressing.

Cutting tools
Cold isostatically pressed high-speed steel parts
processed through liquid phase sintering

Diamond cutting blade Cobalt provides a

tough bond for the discrete diamond
grains. Diamond has a high hardness for
cutting operation, but eventually will dull
and transforms to graphite. So the cutting
tool continually erodes during use to
expose new diamonds with fresh cutting
surfaces.
It is made by compacting mixed diamond
grains and cobalt powder. Hot pressed to
full density, 800 C for 15 min.

Machine tools: Non-cutting applications

Metal forming tools: Hot forming and cold forming
PM high-speed steel is used
Cemented carbides are used for making dies for drawing wire,
rods, bards, tubes, etc.

Power generation
Application based on fossil fuels: Hot isostatically pressed PM
rings (12% Cr steel) with enhanced toughness, fatigue
strength and creep rupture strength are very useful.
Application based on nuclear fuels: Sintered oxide nuclear
fuel UO2.
The level of open porosity should be low, <1%

Fuel cells: Anode, cathode and electrolyte

Solid Oxide Fuel Cell (SOFC) Advantage: all solid-state
construction, high electrical conversion efficiency.
Electrolyte: Thin layer (100-150 m) of ZrO2 with 8-10 mol% Y2O3
Cathode: Ni-based cermets
Anode: Electronically conducting ceramic lanthanum magnetite
LaMnO3

Porous PM products
Porous bearings or oil-impregnated self-lubricating bearings:
Oil is forced out with the running of shaft due to the
temperature rise. When the rotation stops and bearing cools,
the oil is re-absorbed by capillary action. Lubricant may lasts
for life time of the bearing.
Metal filters: The filter profile is formed by a loose packing of
the powder (spherical) in the mold.
Bronze, copper, nickel, stainless steel, titanium, etc.
Used in filtration of fuel oils, chemical solutions and emulsions.

Sintered cupro-nickel is used in the bottled gas industry as a

filter in the flow direction and flame arrester in the other
direction. Also used in aircraft cabin air circuits.
Porous nickel sheets are used in the production of batteries
and fuel cells.

Friction elements
Friction elements fitted with sintered metals and produced in
the form of discs and section linings.
Disc-shaped elements are mainly used in friction assemblies
working with lubrication
In clutch and brakes
Copper-base and Iron-base sintered materials
Aircraft brake pad

Heavy duty clutch

Electrical materials
Electrical contact materials: They should have good electrical
and thermal conductivity
Metal-metal systems: Ag-Ni, W-Ag and W-Cu
Metal-metal compound: Ag with oxides of Cd, Zn, Sn and Cu
Metal-non-metal: Al-10% graphite

Electrical lamps: Tungsten filaments in incandescent electric

lamps.
Electrical lamps: A fully dense polycrystalline alumina tube is
used to contain corrosive plasma in sodium vapour lamp.

Tungsten lamp filament

Tungsten ore is formed into an ammonia
compound which is calcined (oxidized) and then
reduced in hydrogen. The resulting powder is 1 to
10 micron in size. Dopants are added to retard
grain growth at elevated temperatures. The
powder is pressed into bars at pressure up to
1000 MPa. Presintering at 1200 C, final sintering
at 2200 C to 2800 C for 30 min, atmosphere
hydrogen to reduce oxides. Further consolidation
are performed by forming techniqes.
Wire drawing is performed at 400 to 800 C.

Dielectrics
Piezoelectric ceramics are extensively used in various
applications: control of oscillator frequencies in
communication industry, high-voltage step-up transformers,
sonar, medical ultrasound, ultrasonic cleaning, etc.
Sintered polycrystalline barium titanate

Capacitors
Solid tantalum capacitor it involves making a porous
tantalum pellet by pressing and sintering tantalum powder
Manufacturing steps are sensitive to the physical properties of the
tantalum powder

Magnetic materials
Soft magnetic materials: Sintered Fe-P alloy, oxide ferrites
Hard magnetic materials: used in compasses, recorders, speed
meters, fan and toy motors, aircraft motors and generators,
dynamos, etc.
Hard ferrites are extensively used, produced from ferrite powders
using PM techniques.

Some more
Oxygen sensor: Conductive ceramics, e.g., TiO2 (exhaust sensor for
automobiles). In order to shorten response time of conductivity
with change in oxygen activity, a porous TiO2 element is used.
Thermal management: Because of miniaturization in electronic
component, efficient thermal management has become crucial
Composite materials based on refractory metals (tungsten, molybdenum)

Metal foams:
Bio-implants: Sintered metallic and ceramic implants

Stainless steel for replacing the head and neck of a femur

Sintered porous Ti dental implants
Porous bio-ceramics alumina and hydroxyapatite

Pacemaker electrode
Application of porous
materials in tissue
attachment to biomedical
devices, including
pacemaker electrode and
artificial joints or bones.

It is fabricated by compaction of platinum powder

around the electrode. The 30200 m pores allow
the heart muscle to penetrate and stabilize the
electrode location.