Powder Metallurgy

Examples: dental filings, oil-less bearing

transmission gears
gears, orthopaedic implants
implants.
Typical 5 passenger car: 40 lb of PM parts.
Commercial airplane engines: 1500-5000 lb PM
Cost
C saving
i off 40% comparedd to traditional
di i l metalworking
l
ki processes.
Some superior mechanical properties.

Powder Metallurgy
SME Video:
http://www youtube com/watch?v=1Mjsi2F2MrY
http://www.youtube.com/watch?v
1Mjsi2F2MrY

Production of PM Parts
Blending and Mixing of
powder
Compaction
C
ti
Sintering
Secondary operations
Densification
D ifi i andd sizing
i i
Impregnation and
infiltration
Heat
H t treatment
t t
t andd
finishing

Blending & Mixing of Powders

Blending
Same Chemical Composition Powder
Different Sizes To Reduce Porosity
Mixing
Different Chemical Composition Powders
Produce Unusual Alloys
Additives

Rotating drum rotating double cone screw mixer

blade mixer

Compaction

Compacting Pressure

Pressure, tons/in2

Application

Porous metals and filters

Refractory metals and carbides
Porous bearings
Machine parts
High-density iron and steel parts
feeding

Initial
compaction

Fi l
Final
compaction

3-5
5-15
10-25
20-50
50-120

Green Strength & Density

Green:
Before
f
Sintering
i
i

Part Properties v.s. Density

Copper
powder

Compaction Methods
Single punch restricted depth,
non-uniform density

Double-acting press with

two punches greater depth,
more uniform density
distribution.

Compaction of Stepped Parts

3/
4

original
volume or
11/3*original
density

Multiple punches are

used to produce nearnear
uniform density

1/
2

original
volume or
2* i i l
2*original
density

Isostatic Compaction
Pressure is applied from all directions against the powder in
flexible mold

Sintering

Sintering Procedure

The compressed metal powder is heated to a temperature

below its melting point, but sufficiently high to allow bonding
(fusion) of the individual particles.
Sintering temperatures 70% to 90% of the melting
point of the metal or alloy
p
y
Sintering time

10 min. For iron and copper alloys

upto 8 hrs for tungsten

Sintering

Sintering
Shrinkage

Must be considered in die design

Sintered
Material Density
Depends
green density and the sintering conditions in terms of
temperature,
t
t
time
furnace atmosphere
It is preferable to minimize the increase in density during
sintering.: Accuracy vs Mechanical Strength trade-off!

Why?
This can be achieved by using a powder of high compressibility.

Secondary Operation - Densification and Sizing

To improve density, accuracy and shaping:
Repressing
R
i (coining)
( i i )
Sizing
Heat Treatment

Secondary Operation - Impregnation and

Infiltration
Purpose: improve toughness and strength
Impregnation:
filling the part with oils and fluids from a hot bath.
bath or
filling with polymer resins to prevent seepage of fluid.
Infiltration:
Parts are filled with a molten metal
metal.
Melting point of filler metal must be below that of the PM
part, e.g. copper infiltration.

Structural performance of a PM component

Impact Strength
Tensile Strength
Modulus
M d l off El
Elasticity
ti it
Fatigue Performance
Compressive strength.
C
Creep
Improvements by infiltration and impregnation!

Properties of P/M Parts

M i l
Material
Iron

Form and
C
Composition
ii

wrought
P/M - 49% Fe min
P/M - 99% Fe min
Steel
wrought AISI 1025
P/M
/ - 0.25%C
Stainless
wrought Type 303
ssteel
ee
P/M
/ Type
ype 303
Aluminum wrought Type 2014
P/M Type 201 AB
wrought
ht T
Type 6061
P/M Type 601 AB

Density UTS
Elong.
(%) (103psi)
i) (%)
89
94
84
882
94
94

48
30
40
85
34
90
552
70
48
45
36.5

30
9
15
25
2
50
2
20
2
15
2

Part Design Considerations

WHY?

Design Considerations
Geometry
G
off part must allow
ll ejection
j i from
f
the
h die
di after
f pressing
i
all vertical or near-vertical sides.
Avoid vertical undercuts and holes on ppart sides.
Vertical holes can be of cross-sectional shapes other than round
(e.g., squares) without significant increase in tooling or processing
difficulty.
difficulty
Screw threads cannot be built. If needed they must be machined.
Chamfers and corner radii are possible. Problems are encountered
i punchh rigidity
in
i idi when
h angles
l are too acute.
Wall thickness must be beyond some limit (0.06 in).

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations

Design Considerations (Features to be avoided!)

Impossible
Part ejection!
j

Allowable
Part features!

Design Considerations
Chamfers and radii

Better
Part rigidity!

g at
Fragile
Corners edges!

Design Considerations
Minimum wall thickness of 1.5 mm and minimum hole diameter
of 1.5 mm.

Design Guidelines

High Quantity Production >10,000

Minimum
Mi i
wall
ll thickness
thi k
off 1.5
1 5 mm andd minimum
i i
hole
h l diameter
di
t off
1.5 mm.
Limited geometry to allow die opening.
Built-in
B ilt i chamfers
h f andd radii.
dii
Parts with Smaller Surface Areas in Compression Direction
Designed for Ejection
Examples of PM Design Awards
http://www.youtube.com/watch?v=enyyjG5A0ps

Other Powder Forming Processes Rolling,

Extrusion, Forging
We will just bring extrusion for example.
From room temperature to no more than 100oC
Ceramics
C
i or metals
t l combined
bi d with
ith additives
dditi
andd water
t
Water content ~ <10%
Raw material exhibits plastic behavior
Can
C be
b usedd ffor
Large objects like high voltage insulators
Pipes

P 512

Powder Forming Processes - Extrusion

Advantages
Semicontinuous production
Creates lengths of material with constant cross-section
Disadvantages
Anisotropic material
properties