Introduction:

Metal powder may aggregate of particle be defined as an

of metal characterized by small size.

Usually within the range 1-1000 micron metals in powder form are used for large no of metallurgical application.

Metal powders are very important for the manufacturing Of different types of articles by POWDER METALLURGICAL route. So for that we have to make various types of metal powders. The processes of manufacturing P/M articles economically, depend largely on the physical & chemical characteristics of the initial metal powder. So for that the process by which we get the metal powder is very important. The characteristics of metal powder is very much depend on the powder production method.

Types of methods of powder production:

For the production of metal powders there are so So many methods are available. But generally we are consider two types of methods mainly. They are 1.Physico chemical processes & 2.Mechanical processes.

Physico chemical processes are as under:

1. 2. 3. 4. 5. 6. 7. 8. 9.

Condensation. Thermal deposition. Reduction. Precipitation from aqueous solution. Precipitation from fused salts Hydrometallurgy. Inter granular corrosion. Oxidation & Decarburization. Electro deposition.

Mechanical processes:
1. 2. 3. 4. 5. 6. Machining. Crushing. Milling. Shotting. Grinding Atomization.

Out of these metal powder production methods , for the Production of copper powder electro deposition method is well suited.The reason behind that is it yield very pure and uniform grade of powder which is very much suitable for powder met. Application. There are some advantages of this process on the other processes , that we will see afterward. So here we will see the copper powder production by electro deposition method.

So as we know, this is the electro metallurgical process. Electrometallurgy includes the study the of various metallurgical processes utilizing electricity & electrical effects. The electrical effects can be classified into two categories Electrop-chemical & Thermal. The electrochemical effects are obtained due to conversion of electrical energy into chemical energy. The thermal effects are obtained due to conversion of electrical energy into heat energy. The various electrometallurgical processes are as given below:

I.

II. III. IV. V.

. Anodizing. Electrowinning Electro Electrorefining Electro polishing. electroplating Electro etching. electrodeposi Electro m/cining. Electro grinding

cleaning.

Tion.

Electro deposition production:

method

of

metal

powder

Metal powder can be produced by electrodeposition by solution & fused salts. This method is reversed that the electroplating method. Total 30 metals powders can be produced by this method. They are like Cu, Be, Fe, Sn , Zn, Ni, Cd, etc.There are 3 different types of methods of electrodeposition which are in practical use:

1. Deposition of a hard, brittle mass, which is subsequently ground to powder. 2. Deposition as a soft, spongy substance; only loosely adherent with fluffy texture & easily pulverized by light rubbing. 3. Direct deposition as powder from the electrolyte which drops to the bottom of the cell.

The selection of a suitable cathode material permitting the complete removal of the deposit is of great importance for continuous commercial production of metal powder. The removal of powder from the cathode either continuously or at a frequently intervals is also essential. The electrolytic powder deposited in the powder from which are characterictically crystalline are generally characterized by their dendrite or flake like shape of low apparent density & flow , favourable for pressing due to the tendency for individual particles to readily interlock. The particle size is largely dependent on the conditions obtained during deposition. The low specific gravity of

these powders are greatly treatment & grinding.

improved

by

subsequent

heat

Principles of Electro-deposition of metal powders:

The principles, operation & equipment used in the electro-deposition of metal powders are similar to conventional electroplating & electro winning methods , with the basic difference that operating conditions are so adjusted that.

The metal deposits on the cathode as a powdery or even a spongy material which will give a powder either directly or after light grinding. The metal deposits as coherent but in brittle from which may be mechanically ground to a powder from. Metal over voltage: The metals which deposit with from low metal over Voltage. E.g. Ag, Pb, Zn & Cd tend to from needle like and dendritic outgrowth when deposited from their simple salts. It is easy to obtain them as non-adherent deposit, giving a crystalline powder. The metals which deposit with high metal over voltage e.g. iron group metals, the deposit is brittle because of the co-deposition of finely divided basic material , which can be pulverized to powder form. However , even metals such as copper having low metal over voltage, can be obtained in brittle from by the use of addition agents. Condition causing deposition of metal content of the cathode film:

1.

2. 3. 4. 5.

Initial low concentration of the metal. Low temperature. High current density. Stationary electrolyte. Presence of neutral salts in high concentration.

Formation of basic compound in the cathode film: This generally occurs only in electrolysis with neutral or slightly acid electrolyte. The precipitated flows of hydroxide present in cathode . film may be settled down on the cathode surface. Insulate the metal beneath & prevent it from growing, where as free parts of cathode continue to grow. In this way either or nonadherent deposit can be obtained.

Variables governing size of the powder:

Increase the metal ion concentration. Increase the acid ion concentration. Increase the temperature electrolyte. Increase in interval at which at which deposits is being removed from the cathode. Decreasing in current in current density. Decreasing in circulation rate of electrolyte.

Nature of the powder :

Usually uniform grade or fine, usually within the range of 1 to 30 micron. Dendritioc particles are obtained. Their main characteristic is their purity.

Electrodeposition of metal powder from aquous solutions:

The method is used for the powder of copper & iron . Higher current densities than in electroplating are used. Higher acidity a low metal ion concentration is kept to make the deposition spongy due to H2 evolution. In order to maintain close tolerance of particle size to get uniform grade the equate removal of the powder either continuously or at frequent interval.

Copper powder:
Copper is different from most other metals in that it combines corrosion resistence with high electrical & heat conductivity, Formability, machinability & strength when alloy , Except for high temperature. Copper exhibit good resistence unban marine & industrial atmosphere & water. It has scrap value, the amenability to fabrication by several techniques. gm/cm3 Melting point of Cu is 10830 C & density is 8.94

Usual CuSO4 is used as an electrolyte with Cu plate as anode & antimoniol lead in form of sheet as

cathode, the deposing tank are very similar to those used in continuous electrorefining method. During electrolysis some powder fall to the bottom of the tank while some remains stick the cathode. Which can be brushed off, control of content of the electrolysis which goes high due to electrolysis. Due to less then 100% efficiemcy of cathode make in series of electro-winning tanks using insoluble anode. The dried powder is proceed through classifier a blanding system. The Cu concentration has been considerably effect on current density, apparent density & particle size of the powder.

Electro-plating 1. 2.
3.

4. 5. 6.

Electrolytic copper powder production High voltage, low 1) Low voltage, High current. current. Current density- low. 2) Current density- high. Less H2 evolution. 3) More H2 evolution. Adherent film 4) Non Adherent deposition. deposition. 5) Low metal ion High metal ion concentration. concentration. 6) High acidity. Low acidity. 7) Low temperature.

7. High temperature.

Bath composition:

Electrolyte: CuSO4+ H2SO4 Temperature Circulation rate Electrical condition voltage Anode current density

5-8 g/liter 130-150g/liter 40-500C 5-6gal/min tank 1 volt 538-645 amp/ m2

Modification applied for copper powder production:

Addition agents: Like glues has been used by drawly this resulted in production of a non adherent fine powder as well as in increase in current efficiency. To enhance the separation of powder from the cathode, surface active agent like soap nut solution is added to the electrolyte. This results in automotive falling of deposited copper powder. Main use of electrolytic copper powder of parts by powder metallurgical free.

Advantages:

Comparatively economical method. 2. It is possible to produce the high degree of purity. 3. It has excellent compatibility & sinterability when we talking about powder metallurgy. 4. It is possible to obtain wide range of powder quality by alternating the bath composition.
1.

5. We get high purity powder by this method.

Disadvantages:

1. Time consuming process. 2. High cost of powder due to low production rate. 3. Not suitable for the alloy powder production.

References: A. Corrosion engineering Mars G. Fontana B. Introduction to electrometallurgySaran & Narain. C. www.corrosiondoctor.com. D.Powder metallurgy A K Sinha.