TEAM MEMBERS:

VIDHIDUHITA RAUL
(111021008)

GAYATRI VORA
(111021024)

DEVASHRI VAGHOLKAR
(111021037)
INTRODUCTION
Powder metallurgy is the process of
blending fine powdered materials, pressing
them into a desired shape or form, and then
heating the compressed material in a
controlled atmosphere to bond the material.

Basically a chipless metalworking process,
P/M typically uses more than 97% of the
starting raw material in the finished part and
hence it is an energy and materials
conserving process.
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PROCESS
1
Characterization
2
Powder Production
3
Mixing - Blending
4
Processing - Compacting
5
Sintering Operation
6
Finishing Operation
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A. CHARACTERIZATION AND TESTING
OF POWDERS

Obtaining desired properties in a component
depends on the properties of metal powders used
and hence it is essential to test the powders.

It helps in the selection of the right type of powder
for a given application.
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1. Chemical
Composition
and Impurity
2.Shape, Size
and Distribution
3. Particle
Porosity and
Microstructure
4. Specific
Surface
5.Density 6. Flow Rate
7. Compacting
or Pressing
Properties
8. Sintering
Characteristics
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1. Chemical Composition and
Impurity
Impurities not only affect the component properties
but also influence the pressing and sintering
characteristics and hence its determination is very
important.

It can be determined by several standard
techniques like :
a) Gravimetric Analysis
b) Volumetric Analysis
c) Colourometric Analysis
d) Spectroscopy
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2.Shape, Size and Distribution
It can be measured by the following methods:

1. Sieve Method : It is the simplest method in which sieves of
different mesh numbers are used.

2. Microscopic Method : Optical (2,000 x) and Electron (5,00,000
x) Microscopes are used.

3. Sedimentation Method : Classification is based on the settling
velocities of powders in a fluid.

4. Elutriation Method : The metal powder is allowed to settle in a
moving liquid or gas of a constant velocity to determine size
distribution of fine particles.
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3. Particle Porosity and Microstructure
It is determined by using microscopy by mounting the
powders in a suitable medium.

1. HOT MOUNTING : Powder + Bakelite
The medium is mounted, polished, etched, washed with
water and alcohol and dried using blast of hot air and then
examined under microscope.

2. COLD MOUNTING : Powder + Polymeric Liquid + Hardener
The medium is poured in a steel tube in which the liquid
polymerizes and becomes hard in 10-15 mins. Then it is
polished, etched, washed and examined.
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4. Specific Surface
Total surface area of powder per unit weight
(cm2/gm).

The compacting and sintering properties are highly
dependent on the contact area.

Methods of evaluation :
1. Permeability Method
2. Adsorption Method
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5.Density
1. APPARENT DENSITY :
It is defined as the mass per unit volume of a loosely or
unpacked powder.
It includes internal pores only and strongly influences the
pressing characteristics.
It is measured by using standard flow meter funnel or
volumeter.

2. TAP DENSITY :
It is the apparent density of the powder after it has been
mechanically shaken or tapped until the level of powder
remains constant.
It is measured by Ro tap machine.
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VOLUMETER
RO-TAP MACHINE
6. Flow Rate
It is defined as the rate at which metal powder will flow under
gravity from a container through an orifice having specific
shape and size.
It is measured by using a flow meter which is a conical brass
funnel with an internal angle of 60 .
It depends on :
Size and shape
Distribution
Amount of adsorbed gases
Moisture
Coefficient of friction
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7. Compacting or Pressing Properties
It is represented in terms of :

Compressibility :
Ability to undergo deformation under the
applied pressure.

Compactibility :
The minimum pressure required to produce a
compact.
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8. Sintering Characteristics
The sintering characteristics and quality can be
determined by testing the following properties :

Dimensional Change i.e. % Shrinkage
Density and Porosity
Mechanical Properties
Microstructure
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B. POWDER MANUFACTURING
There are various ways to manufacture powder
and each method gives a power of different
size, shape, distribution and has different
characteristics.
Therefore, a right type of powder in the correct
proportion should be used for obtaining the
desired properties in the final sintered product.
The proper choice of method depends on the
type of raw material, desired properties, final
component and economy of the process.

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MECHANICAL
PROCESSES
PHYSICAL
PROCESSES
CHEMICAL
PROCESSES
ELECTRO-
CHEMICAL
PROCESSES
POWDER
MANUFACTURING
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MACHINING
CRUSHING
MILLING
SHOTTING
GRAINING
AUTOMIZATION
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TYPES OF CRUSHERS
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MILLING
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SHOTTING
Solidification by air or
neutral gas
GRAINING
Solidification by
water
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Molten metal is poured on a vibrating screen
and the liquid droplets are solidified.
In both the methods powders contained are
coarse

Other pulverization methods required.
AUTOMIZATION
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, aluminium, zinc and tin
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2. PHYSICAL PROCESSES
CONDENSATION
THERMAL DECOMPOSITION
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CONDENSATION
Metal vapours condensed to obtain powder

Highly suitable for volatile metals

Powder shape is nearly spherical
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THERMAL DECOMPOSITION
Thermal decomposition of carbonyl vapours.

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Fe 5CO Fe(co)
5

Fe(co)
5

Fe
5CO
200 to 270
70 to 200 atm

Carbonyl
vapours
Solid metal
Carbonyl 150 to 400
1 atm

Metal powder
3. CHEMICAL PROCESSES
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REDUCTION
Metal compound is reduced by suitable reducing
agent to obtain metal powder.

Example: Chromium powder is produced by
reduction of chromium oxide with Mg.

Powders obtained are fine.

Shape of particles is irregular.
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INTERGRANULAR CORROSION
Grain boundaries corrode faster than grains.


Grain boundary area of metal under interest is
corroded by a suitable electrolyte so as to
separate out grains from the polycrystalline metal.
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PRECIPITATION FROM AQUEOUS
SOLUTION
Less noble metal displaces more noble metal
from an aqueous solution containing ions of
more noble metal.

Example: Silver is displaced from a silver nitrate
solution by Cu or Fe.

Excellent purity.

Dendritic shape.

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4. ELECTRO-CHEMICAL PROCESSES
Powder obtained by electro deposition from aqueous
solution.

Similar to electroplating.

Conditions favorable for powder formation on
cathode:
1. High current density
2. Low metal ion concentration
3. High acidity
4. Low temperature


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Types of Electrodeposition
Hard and
brittle, which
is
subsequently
ground to
powder
Soft and
spongy,
loosely
adherent and
fluffy texture
which is
powdered by
light rubbing
Direct
deposition as
powder in
bottom of the
cell
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C. POWDER BLENDING
Powders of metals and non-metals are carefully
blended to obtain uniform mixture.
This is essential for obtaining the desired
properties.
Lubricants are used to reduce friction between
die walls and the punches.
Various types of blenders and mixers are
available to suit particular requirements of the
components produced.
For better mixing Tumbling action is necessary
and hence Y cone or Double cone Blender is
used.
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Types of Blenders
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D. POWDER COMPACTING
Powder compaction is the process
of compacting metal powder in a
die through the application of high
pressures.
The tools are held in the vertical
orientation with the punch tool
forming the bottom of the cavity.
The powder is then compacted
into a shape and then ejected
from the die cavity.
The density of the compacted
powder is directly proportional to
the amount of pressure applied
which should be between 1 to 150
kg/mm.
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Compaction Cycle
1. Cycle Start
2. Charge die
3. Compaction begins
4. Compaction complete
5. Ejection of compact
6. Recharging of die

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Compacting Tools
Tooling must be designed so that
it will withstand the extreme
pressure without deforming or
bending.
Materials used should be
polished and wear-resistant.
There are 4 major classes of
tools:
1. Single Action Compaction ( for thin,
flat components)
2. Opposed Double Action with Two
Punch Motions (which
accommodates thicker components)
3. Double Action with Floating Die
4. Double Action Withdrawal Die
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E. SINTERING
Solid state sintering is the
process of taking metal in the
form of a powder and placing it
into a mold or die.

The material is placed under a
high heat (~80% of melting
temperature) for a long period
of time.

Under heat, bonding takes
place between the porous
aggregate particles and once
cooled the powder has bonded
to form a solid piece.
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Sintering proceeds in
three stages.
1. Neck growth proceeds rapidly
but powder particles remain
discrete.

2. Most densification occurs, the
structure recrystallizes and
particles diffuse into each
other.

3. Isolated pores tend to become
spheroid and densification
continues at a much lower
rate.
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`
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Types of Sintering
Two types of sintering :-

Solid Phase Sintering : The
compacts are heated above
recrystallization temperature
of low melting metal.

Liquid Phase Sintering : The
compact is heated above the
melting point of one of the
alloying elements. Alloying
may take place at the
interface of the particles.

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F. FINISHING
Repressing:
Additional compacting operations, performed
under high pressure in presses (coining, sizing).

Impregnation:
Utilizes inherent porosity of P/M components by
impregnating them with a fluid (oil).

Infiltration:
A slug of lower melting point metal is placed
against the sintered part, the assembly is heated
to melt slug. By capillary action, the liquid slug
fills the pores of the sintered part.
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ADVANTAGES
Combinations of metals and non metals
powdered parts can be manufactured.

High Dimensional accuracy.

No material is wasted as scrap.

Porous parts and cemented carbide tools can
be produced which is not possible by any other
method.

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Highly qualified or skilled person is not required.

Large scale production is economical and gives
efficient results.

Eliminates numerous machining operations.

Powder metallurgy parts can be easily brazed,
welded , soldered.

Fine Surface finish is achieved.

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RECOGNISED GREEN TECHNOLOGY
In an initiative undertaken by
the Metal Powder Industries
Federation, the PM industry is
proclaiming to the
manufacturing community
that powder metallurgy is a
recognized "green"
technology.

Being sustainable is a way of
life andfor many of us in the
PM industrybeing green is
now a way of doing business.
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DISADVANTAGES
High tooling costs and expensive raw materials.

Difficult storing and handling of powders (degradation
with time and fire hazard with particular metallic
powders).

Not economical for small scale production.

Products have poor ductility, purity of powder is low
and they show poor plastic properties.

Porosity makes it difficult to obtain some mechanical
properties.
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HOT ISOSTATIC PRESSING (HIP)
Hot Isostatic Pressing of encapsulated powder
metal produces net or near net shape parts with
special particle properties.
The process takes place well below the melting
point of the material, typically resulting in a very
fine grained structure.

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ADVANTAGES OF HIP PROCESS
Hot Isostatic Process P/M parts are:

Isotropic
Densification of powdered metal parts
Elimination of porosity
Improved mechanical properties
Little or no secondary machining
Decreased scrap loss


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APPLICATIONS
Powder Metallurgy finds wide applications in the
industry and several market segments
offer potential growth areas for powder metallurgy
manufacturing techniques.

Automotive components
Aerospace
High temperature applications
Healthcare sector
Defence
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Automotive Components
Manufacture electrical contacts, crank shaft, piston
rings, connecting rods, clutches, brakes, dynamos,
etc.

Titanium is in exhaust systems using cheap
commercially pure (CP) sheet. Turbochargers,
valves and springs are usually made from titanium
alloys.

Used as a fabrication technique for automotive
components, with many cars containing up to 8-30
kilograms of parts made this way.
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Aerospace
Metal powders play an important role in rockets, missiles,
satellites and space vehicles.
Metal powders of Be, Al, Mg and Zr are used as solid fuels in
rockets and missiles.
Tungsten parts are used in plasma jet engines and ion
engines operated at about 1800 C.
Net-shape HIP titanium Powder Metallurgy products have
been developed for turbine applications where conventional
processing (involving machining) is very wasteful of material
and the Powder Metallurgy route can offer cost benefits.

Airframe sector:
There is also growing interest in the use of titanium Powder
Metallurgy in the airframe sector.
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High Temperature Applications
Components made of W, Mo and Ta by powder
metallurgy are widely used in electric light bulbs,
fluorescent bulbs, radio valves, mercury arc
rectifiers and X ray tubes in the form of filament,etc.

Refractory metal carbides are used for dies, rolls,
cutting tools, etc. at high temperatures.

Production of super alloys is also possible by
powder metallurgy.
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Healthcare Sector
Titanium and titanium alloys are ideally suited to
medical implants because titanium is
biocompatible and inert to human body fluids.
MRI scanners used large quantities of rare earth
permanent magnets, processed from powders.
Surgical instruments and dental implants are
produced.
Customized medical implants using additive
manufacturing and in producing porous implant
structures (to match bone stiffness and to aid
osteo-integration) by PM processing.
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Defense Applications
Metal powders play an important role in military
and national defense systems.

They find use in missiles, rockets, cartridge cases,
bullets, etc.

Also used in military pyrotechnics like tracers,
incendiaries, etc.
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Powder Metallurgy Products
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Oil-impregnated Porous Bronze Bearings Connecting Rods
Gears

1. Self Lubricating Bearings
Self-lubricating oil-impregnated PM bearings find their
applications in mechanical and electromechanical devices,
where sliding processes, especially rotary motions, are
occurring.
Friction and wear are reduced, and liquids can carry away
both frictional heat and wear debris generated during the
sliding process.
When the shaft is at rest all the oil is retained in the pores and
the load is sustained by direct metallic contact between the
two surfaces. At the beginning of movement the direct
metallic rubbing between bearing and journal with its high
friction coefficient raises the temperature rapidly.

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2. Cermets
Cermet is "a heterogeneous combination of metals or alloys
with one or more ceramic phases in which the latter
constitutes approximately 15 to 85% by volume and in which
there is relatively little solubility between metallic and ceramic
phases at the preparation temperature".

Cermets originally were used for cutting tool applications.

Refractory behavior, strength, and corrosion resistance of the
ceramic with the high ductility and thermal conductivity of the
metallic phase are some properties.

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3. Cemented Carbides And
Cemented Carbide Tipped Tools
Tungsten carbide (WC), also referred to
as cemented carbide, is a composite
material. Tungsten carbide powder,
generally ranging in proportion between
70%-97% of the total weight, is mixed
with a binder metal, usually cobalt or
nickel, compacted in a die and then
sintered in a furnace.

Carbides are brittle materials since it
exhibits little or no plastic deformation
preceding the initiation of a crack and
total failure..

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Withstand all forms of wear (including
sliding abrasion, erosion,
corrosion/wear and metal-to-metal
galling) and exhibit a high degree of
toughness.

It exhibits high compressive strength,
resists deflection, and retains its
hardness values at high temperatures,
a physical property especially useful in
metal-cutting applications.

It provides long life in applications
where other materials would not last or
would fail prematurely.
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