Powder Metal

Processing
Manufacturing
Processes
By:
Dr.Behzad Heidarshenas

Outline
Introduction
Powder Manufacturing
Powder Metallurgy Process
Sintering
Other Powder Metal Processes
Powder Metal Products
Powder Metallurgy Design

Powder Metallurgy

Powder Metallurgy
Metal
Powder
Metal Product

Examples of Powder
Metal Products
Gears
Cams
Cranks
Bearings
Roller bearing cages
Housings
Light bulb filaments
Sprinkler mechanisms

Powder Metal Materials

Elemental
A pure metal, most commonly
iron, aluminum or copper
Prealloyed
An alloy of the required
composition, most commonly
copper alloys, stainless steel
or high-speed steel

Powder Manufacturing
Conversion of molten metal to
powder
Atomization

Powder Manufacturing
Other methods of producing
powder:
- Chemical reduction of
particulate compounds
- Electrolytic deposition
- Pulverization or grinding of
brittle materials
- Thermal decomposition
- Precipitation from solutions
- Condensation of metal vapors

Particle Shape

Particle Size
The process of separating particles
by size is called classification

Particle Size
Micrograph of screened powder particles, showing
that particles may be longer than the mesh is wide

Particle Size
Mixing particles of different sizes allows decreased
porosity and a higher packing ratio

void

smaller, more numerous voids

voids filled by smaller particles,

small voids remain

Powder Metallurgy
Process

Blending and Mixing

Blending
Combining powders of the same material
but possibly different particle sizes
Mixing
Combining powders of different materials

Compaction
High pressure is applied to squeeze
the powder into the desired shape

Example of a Powder
Press

Other Powder Metal

Processes
Cold Isostatic Pressing
Hot Isostatic Pressing
Injection Molding
Powder Rolling
Powder Extrusion
Plasma Spraying

Isostatic Pressing
Uses pressurized fluid to compress the
powder equally in all directions

Cold Isostatic Pressing

Compaction performed at room
temperature
Hot Isostatic Pressing
Performed at high temperatures and
pressures

Example of an Isostatic
Press

Injection Molding
The powder is mixed with a binder
and molded, and the binder is
removed before sintering

Powder Rolling
Powder is compressed in a rolling mill
to form a strip

Powder Extrusion
The powder can be extruded within a
container or after being formed into
billets

Plasma Spraying
Uses a plasma arc to propel molten
droplets at a surface at a high
velocity, forming a high-density
structure

Plasma Spraying

Sintering
Heats the powder below the melting
point to allow solid-state diffusion
and bond the particles together

Sintering
Diagram of particles in sintering, showing the
possible movements of atoms

Sintering

Sintering

Sintering Production
Lines

Examples of Sintering
Production Lines

Sintering
Strength of sintered structures as related to density,
showing that the strength is higher when the density
is higher (less residual porosity)

Powder Metal Products

1. Porous or permeable
2.
3.

4.

5.

products
Products of complex shapes
Products made of materials
that are difficult to machine or
have high melting points
Products which require the
combined properties of
multiple materials
Products in which powder
metallurgy produces superior
properties

Powder Metallurgy
Design
1.
2.
3.
4.

5.

The shape must permit removal

from the die
The shape should not have thin
walls or sharp corners
The shape should permit the
construction of strong tooling
The shape of the part should be
within the thickness range for
which the powder can be properly
compacted
The part should have as few
changes in section thickness as
possible

Powder Metallurgy
Design
6.

7.
8.
9.

Parts can be designed to take

advantage of the capabilities of
the powder metallurgy process
The design should be consistent
with available equipment
Consideration should be given for
product tolerances
Design should consider the
dimensional changes that occur
after pressing, such as shrinkage
during sintering

Powder Metallurgy
Design

Powder Metallurgy
Design

Powder Metallurgy
Advantages
1. Elimination/reduction of
2.
3.
4.
5.
6.

machining
High production rates
Complex shapes can be
produced
Wide composition variations
are possible
Wide property variations are
possible
Scrap is eliminated or
reduced

Powder Metallurgy
Disadvantages
1. Inferior strength properties
2. Relatively high die cost
3. High material cost

Summary
Powder metallurgy can create
parts that would otherwise be
difficult to form, including those
with complex shapes or
porosity
Sintering bonds particles
together by allowing atoms to
move, forming necks and grain
boundaries between the
particles