IE560 ASSIGNMENT 10: POWDER METALLURGY

Foreground:

The majority of Powder Metallurgy (P/M) produced parts contain pores. While this may be advantageous in some
cases for e.g., when using P/M to make self-lubricating bearings (pores impregnated with oil), for many
applications, it is an impediment as the lower density (compared to full density of 7.8 g/cc for ferrous alloys) on
account of pores imparts relatively poor mechanical properties when compared to wrought or casted products.
Typically, density of around 7.0 g/cc can be achieved by using conventional P/M processes (single press and
sinter). The effect of density/porosity on the mechanical properties is depicted below: -

Fig. 1 Fig. 2: Fatigue Strength Comparison

Therefore, permissible density is application dependent with higher load applications calling for higher density
products. In view of above, quite a few secondary processes and powder processing techniques have been
developed to increase the density of P/M products (refer fig. 3): -

Fig 3. Mapping of Full-Density Processes

Since, die compaction based processes are the most prevalent (due to high production rate and wider range of
product size and shape compatibility compared to other processes) and our P/M product portfolio is based on such
processes, we will be focusing on the following techniques that are an extension of this method: -

a) Hot Pressing/Compaction: A high pressure, low strain rate process done at temperatures high enough to
induce sintering and creep processes. Powder, die or both may be heated as per requirement. Lubricant
and binder may be added to improve manufacturability and enhance properties.
b) Double Press/Double Sinter (DPDS): Once pressed, sintering is done at lower temperatures to avoid a full
metallurgical bond. Graphite that was added to the mixture fuses into metal matrix generating voids.
Another cycle of pressing and sintering gives the final product.
c) Copper Infiltration: Filling of pores of compact with open porosity using external pressure and/or capillary
forces
d) Powder Forging: pore elimination through plastic yielding by forging

Process Comparison:

UHD processing promoted by M/s Keystone is basically a Double Press/Double Sinter (DPDS) process. A quick
look at the density vs relative plot for the discussed processing techniques in Fig 4 shows that density range of
7.2 ~ 7.5 g/cc can be achieved by this process. This is a significant improvement from conventional P/M method.
However, this method is surpassed by Powder forging (7.6 ~ 7.8 g/cc) and Copper infiltration method (7.0 ~ 7.6
g/cc). ANCORDENSE (form of Hot Compaction marketed by M/s Hoeganaes Corporation) achieves comparable
density (7.2 ~ 7.4 g/cc). A comparison of the cost shows that DPDS processed product is almost 1.5 times costlier
than conventional method. However, it is much lower than powder forging (by almost 25%) and is comparable
to Cu infiltration method. Hot Compaction is the least costly amongst the methods discussed.

Fig. 4
An important point to note is that the performance gain in copper infiltration is not proportional to the increase in
density due to the presence of soft phase (Cu). On the other hand, all mechanical characteristics except ductility
of powder forged materials are often superior to even wrought products due to work hardening. Also, DPDS is
restricted to simpler shapes compared to other processes.

Conclusion:
DPDS process (called UHD by Keystone) is not restricted to M/s Keystone and is used by other companies like
GKN Sinter Metals. M/s Keystone have however successfully used it to produce helical gears and timing
sprockets given the shape limitations of the process. Having said that, our studies show that UHD processing
results in significant increase in density/properties, but still does not surpass Powder forging. Therefore,
performance products that demand no compromise in mechanical properties should be made from powder forging.
Products that require density in the range of 7.2 ~ 7.5 g/cc can be made with DPDS/UHD. But, ANCORDENSE
process/hot compaction gives similar performance at a lower cost. Therefore, we recommend exploring
ANCORDENSE process/hot compaction for such products.