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Definition
Powder metallurgy is the art and science of producing fine metal powders and
then making objects from individual, mixed or alloyed metal powders with or
without the inclusion of non-metallic constituents.
Or
Blending
Die compacting
Sintering
Optional Optional
secondary secondary
,anufacturing finishing
Finished P/M
products
1.Atomization
2.Reduction
3.Crushing
4.Milling
5.Shotting
6.Electrolysis.
1.Atomization
•The process of metal spraying against a stream of compressed air or inert gas is
Atomization.
•It is an excellent means of producing metal powders from many of the low
temperature metals such as lead, aluminum, zinc and tin.Fig.
2. Reduction
•In reduction process, the compounds of metals usually oxides like iron oxides
are reduced with CO/ H 2 at temperature below melting point of metal.
Crushing.
•Process of passing the metal powders against two rollers so that the metal
powders are crushed to required size.
Milling.
•Milling is carried out by using equipments such as ball mill, rod mill, impact mill,
disk mill etc.
Shotting
•The process of pouring molten metal through a sieve or orifice and cooling by
dropping into water is known as shotting.
Electrolysis.
•The above figure (a) shows the container in which the powder to be mixed is
added
•The blade continuously rotates and mixes the powder.
•Figure (b) shows a rotating drum in which powder is filled and the drum keeps
on rotating and simultaneously mixing the powders.
•Wet or dry mixing is generally employed.
•For wet mixing water or dry solvent is used to obtain better mixing.
•Blending and mixing is necessary for
Addition of lubricants coats the powders and reduces die wear and lowers
pressure required for pressing of powders.
Mixing powders of different materials
Obtaining uniform distribution of particle sizes.
1) Die pressing.
It consists of upper punch and lower punch as shown in figure.
Powder is filled on the space above lower punch.
Upper punch applies high pressure to the powder.
Finally the green compact powder is received as shown in figure.
2. Roll pressing.
Two rolls of appropriate sizes are used.
Stream of powder is guided, so that the rolls are able to apply the
necessary compacting pressure in a continuous sequence.
3. Extrusion method.
Ram is used for applying force.
Two dies are used for achieving proper thickness.
As seen in the figure the green compact is received which is further send
for sintering process.
D. PRESINTERING the powder
I. Powder metallurgy is used to make parts from materials that are very
difficult to machine.
II. When some machining is required on such parts, Presintering is
done before actual sintering operation.
III. Compact is heated for a short time at a temperature below sintering
temperature.
IV. Presintering removes lubricants and binders added to powders
during blending operation.
V. After Presintering, the part acquires sufficient strength to be handled
and machined without difficulty.
SINTERING
•It is the term to understand the type and percentage of impurities that the
powder contains.
Particle shape.
Various shapes of metal powders observed according to the method of
production
4.Particle porosity: -
•Ratio of the volume of the pores (empty spaces) in the powder to the bulk
volume (filled space).
•Porosity increases stress in the part so it is not desirable.
Particle microstructure.
•For observation of microstructure, the powder metallurgy part is first polished,
then etching of the surface similar to the dye penetrant method is done which will
show the microstructure of the powder metallurgy part
6.Specific characteristics -
Specific surface– total surface area of particle per unit weight.
Apparent density– packing density – mass per unit volume of loose powder or
unpacked powder.
Tap density – density of powder after it is packed.
Flow rate– Rate with which metal powder flows under gravity from container.
(speed of flowing of metal powder in certain time)
Green density– density of compacted powder before sintering (i.e. density of
powder before heating)
Green strength– strength of metal powder before it is sintered (heated).
Green spring- after the ejection of compacted powder from die, expansion of
powder takes place. The difference between size of compact and die is green
spring.