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Chapter 17
Powder Metals
Commonly used metals in P/M Iron,Tin, Copper, Aluminum, and Nickel It is a completive process with forging and machining Parts can weigh as much as little as 2.5Kg or up to 50Kg
Powder Metallurgy
a c
Fig: (a)Examples of typical parts made by powder-metallurgy processes. (b) Upper trip lever for a commercial irrigation sprinkler, made by P/M. This part is made of unleaded brass alloy; it replaces a die-cast part, with a 60% savings. (c) Main-bearing powder metal caps for 3.8 and 3.1 liter General Motors automotive engines.
Fig: Particle shapes in metal powders,and the processes by which they are produced.Iron powders are produced by many of these processes
Powder Particles
Fig : (a) Scanning electron-microscopy photograph of iron-powder particles made by atomization. (b) Nickel-based superalloy powder particles made by the rotating electrode process.
Fig : Methods of metal-powder production by atomization;(a) melt atomization; (b) atomization with a rotating consumable electrode
Fig: Methods of mechanical communication, to obtain fine particles: (a) roll crushing, (b) ball mill, & (c) hammer milling
Blending Powders
Blending powders is the second step in the P/M process Powders made by different processes have different sizes and shapes and must be well mixed Powders of different metals can be mixed together Lubricants can be mixed with the powders to improve their flow characteristics
Fig: Some common equipment geometries for mixing or blending powders. (a) cylindrical, (b) rotating cube, (c) double cone, and (d) twin shell.
Equipment
Uses 100-300 ton press Selection of the press depends on the part and the configuration of the part
Fig: A7.3 MN (825 ton) mechanical press for compacting metal powder.
Isostatic Pressing
Cold isostatic Pressing (CIP) Metal powder is placed in a flexible rubber mold Pressurized hydrostatically Uses pressures up to 150 KSI Typical application is automotive cylinder liners
Fig: Schematic diagram, of cold isostatic, as applied to forming a tube.The powder is enclosed in a flexible container around a solid core rod.Pressure is applied iso-statically to the assembly inside a high-pressure chamber.
Isostatic Pressing
Hot Isostatic pressing Container is made of highmelting-point sheet metal Uses a inert gas as the pressurizing medium Common conditions for HIP are 15KSI at 2000F Mainly used for super alloy casting
Fig: Schematic illustration of hot isostatic pressing.The pressure and temperature variation vs.time are shown in the diagram
Extrusion has improved properties and parts my be forged in a closed die to get final shape Pressureless compaction gravity filled die and used to make porous parts Ceramic molds molds are made by made by investment casting and the powder is compressed by hot isostatic pressing Spray deposition shape-generation process
Sintering
Sintering - Green compacts are heated in a furnace to a temperature below melting point Improves the strength of the material Proper furnace control is important for optimum properties
Fig: Schematic illustration of two mechanism for sintering metal powders: (a) solid-state material transport; (b) liquid-phase material transport.R= particle radius, r=neck radius, and p=neck profile radius
Sintering
Particles start forming a bond by diffusion Vapor-phase transport heated very close to melting temperature allows metal atoms to release to the vapor phase Mechanical Properties
Fig: Examples of P/M parts,showing poor designs and good ones.Notes that sharp radii and re entry corners should be avoided and that threads and transverse holes have to be produced separately by additional machining operations.
Process Capabilities
It is a technique for making parts from high melting point refractory metals High production rates Good dimensional control Wide range of compositions for obtaining special mechanical and physical properties
Process Capabilities
Limitations
High cost Tooling cost for short production runs Limitations on part size and shape Mechanical properties of the part
Strength Ductility
Shaping Ceramics
Processing ceramics Crushing or grinding the raw materials in to very fine particles Mixing with additives Shaping, drying , and firing the material
SLIP CASTING