Chapter 18:

Powder Metallurgy
18.1 Introduction

the given to the process

Powdermetallurgy is
name

powdered materials a r e blended,

by which fine heated to
and then
pressed into a desired shape,
bond surfaces
amounts of small,
Typically used when large a r e required
intricate parts with high precision
material waste and unusual mixtures can be
Little
utilized
automotive industry, household
Used for parts in the
equipment (to name a
appliances, and recreational
few)
18.2The Basic Process
uFour basic stepps Elemental or alloy
metal powders
Additives
(lubricants or binders)
a 1. Powder manufacture
Blending
a2. Mixing or blending
3. Compacting Compaction

4. Sintering Sintering

Optional secondaryY Optional secondary

manufacturing finishing
Figure 18-1 Simplified flow chart of the
basic powder metallurgy process. Finished
P/M product
18.3 Powder Manufacture

are highly
Properties of powder metallurgy products
powders
dependent on the characteristics of starting
characteristics
Someimportant properties and
Chemistry and purity
Particle size
oSize distribution
Particle shape
Surface texture
Useful in producing prealloyed powders
Each powder particle can have the desired alloy
composition
Powder Manufacture

commercial powder is produced

by
The majority of
some form of melt atomization
metal is fragmented
Atomization is a process where liquid
into paticles
into small droplets that cool and solidify
Inert gas Vacuum

Rotating
consumable
Ladle Tundish Figure 18-2 Two
electrode
Spindle methods for producing
Atomizing gas or

,water spray metal powders: (a)

melt atomization and
Nonrotating (b) atomization froma
tungsten Metal particles
electrode
rotating consumable

Atomizing
electrode.
chamber Metal
particles Collection pórt
(b)
(a)
Additional Methods of Powder
Manutacture
Methods
Chemical reduction of particulate compounds
Va Electrolytic deposition
O Pulverization or grinding
particulate hydrides
a Thermal decomposition of
solution
a Precipitation from
a Condensation of metal vapors
converted
Almostany metal or alloy can be
into powder
 Solidified Powder
18.4 Rapidly
(Microcrystalline and Amorphous)
atomized liquid is
If the cooling
rate ofan microcrystalline
sized
ultra-fine or
increased,
grains can form
becoming
can solidify without
Some metals materials)
amorphous
crystalline (called
have high strength,
Amorhpus materials can
resistance, and reduced
corrosion
improved
r e v e r s e magnetization
to induce and
energy
18.5 Powder Testing and Evaluation

for
Powders should be evaluated for their suitability
further processing
the ease with which powder can
Flow rate measures

be fed and distributed into a die

of a powder's
Apparent density is the
measure

fill available space without external

ability to
pressure
Compressibility is the effectiveness of applied
pressure
is used to describe the strength of
=
Green strength
the pressed powder after compacting
 Blending
Mixing and
18.6 Powder
mixed
with other
powders are achieve
The majority of lubricants
to
and
binders, finished
powders, characteristics
in the
the desired

product during
diffusion must occur and
Sufficient chemistry
uniform
a
sintering to
ensure

structure
can be produced
composites
=Unique can be done
= Blending or mixing operations
either wet or dry
18.7 Compacting
into a
densified
is compacted and
LOOse powder
compact
shape, known as green mechanical presses
done with
Mostcompacting is
and rigid tools also used
are
presses
Hydraulic and pneumatic
for Various Applications
Pressures
Compacting
TABLE 18-1 Typical
Compaction Pressures
Mpa
tons/in.
Application 40-70
3-5
filters 70-200
Porous metals and 5-15
146-350
metals and carbides
Refractory 10-25
275-690
Porous bearings 20-50
(medium-density
iron & steel) 250-275
Machine parts 18-20
and aluminum parts 690-1650
High-density copper 50-120
steel parts
High-density iron and
 STOKES

SUMHUT-

removable die set (right)

metal powders. A
for the compacting of fitted to produce a
another is being
Figure 18-3 (Left) Typical
press set while
die
parts with one
allowsthe machine to be producing Warminster, PA.)
Laval, Inc.,
second product. (Courtesy of Alfa
Compaction Sequence
Powders do not flow like liquid, they simply
force iss
until an equal and opposing
CompresS
created combination of (1)
created froma
opposing force is between the
This
punch and (2) friction
resistance by the bottom
surface
particles and die
Puncn

UU
Feed
shoe Punch

Core

Recharging
4 Compaction Ejection
3 Compaction die
2 Charging f part
1 Cycle completed
begins
(filling) die
start
with powder the functions of the
feed shoe
for a single-level part, showing is solid black.
compaction sequence compacted powder
Figure 18-4 Typical lower punches. Loose powder is shaded;
die core and upper and
rod,
Compaction Sequence

Powders do not flow like liquid, they Simply Is

force
CompresS until an equal and opposing
created
combination of (1)
force is created from a
This opposing and (2) friction
between the
resistance by the bottom punch
particles and die surface
Punch

he

Feeo
shoe
Punch

6 Recharging
4 Compaction 5 Ejection
2 Chargin9 Compaction
CY (ling) ae begins
completed of part die
Start

with powder
functions of the feed shoe,
for a single-level part, showing the
Figure 18-4 Typical compaction sequence Loose powder is shaded; compacted powder
is solid black.
die core rod, and upper and lower punches.
Additional Considerations During
Compacting
When the pressure is
applied by only one 18-5 Compaction
with a single
moving punch,
density(shaded),
punch, the maximum Figure nonuniform
resultant
showing the movement is the greatest.
where particle
density occurs right highest

below the punch

Surface and decreases

away from punch

the

Forcomplex shapes,
multiple punches with a double-
distribution obtained
Figure 18-6 Density Note the
should be used two moving punches.
acting press and 18-5. Thicker
increased uniformity compared to Figure
compacted.
parts can be effectively
 Effects of Compacting
Pressure, MPa
100 200 300
100 400 500 600

1/2 original volume

0
Lr
Initial conditions
3/4 original volume
or 1-1/3 x original

density
After compaction

b
or 2 x original

density

a)
Fe+
+Cu
of a part with
two-thickness
30
Figure 18-8 Compaction Initial conditions; (b) after
only one moving punch. (a) drastic
compaction by the upper
punch. Note the
0 difference in compacted density.

MO

0
40 50 60 70 80 90
0 10 20 30
Pressure, ksi
Double lower punch
on green
Single lower punch
Figure 18-7 Effect of compacting pressure
but before Figure 18-9 Two methods of compacting
a double-

density (the density after compaction Both involve the

curves are for several
thickness part to near-uniform density.
sintering). Separate controlled movement of two or more punches.
commercial powders.
 Equipment
Classes of Powder Metallurgy

complexity
of
dictates the
The Complexity of the part
equipment classes
into
been grouped
Equipmenthas Class 3

Class

geometries
Figure 18-10 Sample
classes of press-
of the four basic Class 4
and-sinter powder metallurgy
Class 2
increased pressing
parts. Note the
would be required
complexity that
as class increaseS.
Complex Compacting
the
desired,
complex
shape is flexible
mold,
Ifan extremely encapsulated
in a
gas or
powder may be immersed in a
pressurized

which is then
liquid compaction
is known as isostatic
heated prior to
powder is
Process

compaction,
the
In warm
pressing increased in the
can be
The amount of lubricant
reduce friction is a
powder to abrasive, tool
wear
tend to be
Becauseparticles
forming
c o n c e r n in powder