Powder Metallurgy

Powder Metallurgy
1) Powder Metallurgy is a process which involves the mixing of fine metal powder with
the various alloyed or non metallic components and this finally gives result in the
form of useful product
2) In this process
1. Initially metal is made into the powder form
2. Various other elements are mixed with the powdered metal
3. The mixture is then compressed by applying by high pressure which moulds it
into desired shape
4. The shaped mould is then given final finish

5. Inclusion of non metal is done later depending on the requirement

3) Thus powder metallurgy can be summarized as follows
1.
2.
3.
4.
5.

Conversion of metal into powder

Mixing of powders
Compressing or moulding into desired shape
Sintering the pressed powder compacts
Sizing or coining the compact

Advantages of Powder Metallurgy

Some of the advantages of powder metallurgy over other processes are as
mentioned below
1) Using this method products are manufactured at higher rate
2) In this method almost whole of the invested raw material gets utilized in the entire
process
3) Components of any desired shape can be produced using this method
4) The process does not require skilled labour
5) Components produced using this method are found to possess uniform structures
and grain sizes
Disadvantages of Powder Metallurgy
Some of the disadvantages of powder metallurgy are as follows which are observed
under certain circumstances
1) This method is not preferable for forming components which contain metals like Mg,
Al, Zr etc because they may explode when they come in contact with air. Which may
lead to fire hazards
2) This method is not suitable for products that are perfect in context of density
because products pressed at the top are found to be less dense at the bottom
3) This process form components which possess poor resistance to corrosion because
they are porous
4) This process can be only be used for the manufacture of parts having intricate
design because powder metal cannot flow as freely as molten metals
5) This process is not suitable to produce large size components because presses
available for compaction are of limited capacity
Processes or Steps Involved in Powder Metallurgy
The following processes are involved in manufacturing any product by powder
metallurgy
1)
2)
3)
4)

Metal powder formation: Metals are converted in powder of required grain size
Mixing and Blending of powders: Constituents are mixed properly
Compacting the metal powder: Mixture is moulded into desired shape
Sintering: The mould is heated slowly and then cooled which enhances its strength

Metal Powder Formation

1) All the properties possessed by the metal powders totally depend on the method by
which they are manufactured
2) Some of the methods of producing metal powder are as follows
1.
2.
3.
4.
5.

Mechanical communition
Atomization
Reduction of metal oxides
Electrodeposition
Decomposition

1) Mechanical Communition
1. This method is generally employed for the metals which are brittle in nature
2. Powder of brittle metals is mostly suited in powder metallurgy. Powder of ductile
metals can also be produced but it is flaky which is not suitable for powder
metallurgy
2) Atomization
1. In this method liquid metal is passed through a small orifice and jet of liquid is
broken down by jet of compressed gas
2. Modern atomization process involves atomization of metal by striking a rapidly
rotating disc
3) Reduction of Metal Oxides
1. In this method metal is obtained by reduction of a metal oxide by using suitable
reducing agent
2. For carrying out the reduction process either solid or gaseous reducing medium
is used
4) Electrodeposition
1. In this method for the formation of metal powder the principles of electroplating
are used
2. The spongy or brittle metal deposits are obtained at the cathode which are further
processed to convert into metal powder
3. Brittle deposits give angular particles while spongy particles give flattened
particles
5) Decomposition
In this method decomposition of compounds of metal gives metal powder
Mixing and Blending
1) In this stage the metals powders are checked for their particle size
2) Later various metal powders are mixed thoroughly in proper proportion depending
upon the requirement

3) For effective blending, agents such as lubricants, volatilizing agents or non metallic
particles are involved
Sintering
The sintering operations consists of following steps
1) Heating the compacted mixture in the furnaces under controlled conditions
2) Soaking
3) Cooling
Heating is carried out in furnaces below the melting point of all the constituents of the
mixture
Different types of furnaces used for sintering operations are as follows
1. Belt type
2. Sealed high temperature batch type
3. Roller hearth type
Compacting
1) The blended metal powders are then subjected to appropriate compression to impart
them proper shape
2) Compacting is one of the important step in powder metallurgy because it decides the
properties of resultant product
3) Compacting is important because
1. It increases density of compact
2. It produces adhesion and cold welding of powders
3. It facilitates the sintering operation
4) Compacting of blended mixture of metal powder is done by following methods
1. Cold Pressing
2. Powder Injection Moulding
3. Hot Compaction
1) Cold Pressing Technique
There are two types of cold pressing
a) Axial
b) Isostatic

a) Axial Pressing
Diagram:

In

this method the

Powders are compacted
between two punches

b) Isostatic Pressing
In this method the powder is compacted by taking in die and applying high pressure
Powder Injection Moulding
Diagram:

1) The metal powder is converted into a suitable feedstock. Then it is mixed with a
chemical compound which acts as binder
2) The feed stock is heated to melt and then is forced through sprue and runner
channel
Hot Compaction

Schematic Diagram of Hot Compaction

1) Equipment similar to Cold Pressing is used in hot compaction
2) The blended mixture is fed between the punches and then it is compressed under
high pressure
3) Heat or temperature can be maintained either by direct current or by induction
current

Applications of Powder Metallurgy

The powder metallurgy which is widely used as the technology is advantageous. The
method is used to manufacture the following products

1.
2.
3.
4.
5.
6.
7.
8.

Refractory materials
Oil pump gears
Babbit bearings for automobiles
Ferrous products
Electrical contact materials
Diamond impregnated tools
Sintered metal friction material
Alloys like Ferro chromes, woods metal etc

Manufacture of Oxide and Non Oxide Ceramic Powders

The following methods are used to manufacture ceramic powders

1) Solid State reactions

The reaction is mainly used to prepare powder of oxide ceramics. The powder is
made from various suitable compounds which are later subjected to thermal
decomposition.
E.g. Alumina can be made from aluminium hydroxide
2) Gas phase reactions
The method is also preferable for preparation of oxide ceramics. The method
consists of vapour phase decomposition or hydrolysis in flame.
E.g. SiCl4/ TiCl4+ 2H2o

SiO2/ Tio2 + 4HCl

3) Solid Gas reactions

This method is suitable for both oxide and non oxide ceramic powders. The method
involves reaction of metal with oxygen / N2 / NH3 etc. Producing corresponding oxide
or non oxide ceramic powder
4) Melting
The method involves melting of metal in electric are followed by milling which
produces oxide powder of desired particle size
5) Reaction in Solutions
1. In this method the reactant of ceramic powder is first made into aqueous / non
aqueous solution
2. These solutions are then subjected to any of the below mentioned techniques
which gives ceramic powder of appropriate particle size as product
1) For advanced ceramics: Sol gel process
2) For oxide ceramics from organometallic reactant Solution combustion process
3) For ZrO2powder form ZrOCl2solution: Hydro thermal decomposition at high
temperature and pressure