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241 views25 pagesPowdered Metal Design Solutions
Powder metallurgy
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© © All Rights Reserved
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Available Formats
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POWDER METALLURGY Benefits of P/M
How P/M Parts are Made
Secondary Operations
a Choosing the Right Materials
TO sessstnteteenenesenenne swuEngineering Properties
19s srrccrccenreserstn ae Designing P/M Parts
TB ssssssatcsenicon Near-Fully Dense P/M Products
D2 ecnerseunssittctiil Applications of P/M Parts
BB: csresenneenneneniitl How to Specify P/M Parts
DA cesestnssnee The Internet for Design Solutions
2 ossseenBibliography and More Information aOR a Vi)
WHAT IS P/M?
Powder metollurgy—or P/M is « highly developed
method of manufacturing precision metal parts. Made
by mixing elemental or alloy powders and compacting
the mixture in @ die, the resultant shopes are then sin-
tered or heated in « controlled-otmosphere furnace to
bond the particles metalurgicaly. Basicaly a “chipless
metalworking process, PIM typically uses more than
97% of the starting raw material in the finished part
Because of this, P/M conserves energy and materials.
The PIM process is cost effective in producing simple
cor complex parts at, or very close to, final dimensions in
production rales which con range from a few hundred
to several thousand ports per hour As a result, oly
minor. if any. machining is required, PIM parts also may
be sized for closer dimensional control and for
repressed for both higher density and strength
In addition, both ferrous and non-ferrous P/M ports
can be oil impregnated to function as self-ubricating
bearings. Ferrous P/M ports can be resin impregnated
to seal interconnected porosity and then plated with
nother metal if so required: infiltrated with « lower
melting point metal for greater strength and impact
resistance; ond heat treated to o higher strength and
hardness
‘Most P/M parts weigh less than 5 pounds {2.27 kal
although parts weighing as much as 35 pounds |15.89
kal can be fabricated in conventional P/M equipment
‘Many of the early PIM parts, such as bushings ond
bearings. were very simple shopes, as contrasted with
the complex contours and multiple levels which are:
economically produced today.
a 8 8
Taal Sangh 0%!
5
Figure 1- Comparison of material srenaths
P/M SAVES STEPS
Since the PIM process is not shope-sensitive ond nor
mally does not require drafl, ports like coms, gears,
sprockets and levers ore very economically produced.
Previously, designs had offen required that ports such as
«com and a gear, or @ spur gear and pinion gear
be joined together by a secondary assembly method
These additional ossembly steps quite frequently can be
eliminated with multiple level designs which combine
the separate shopes into © one-piece P/M port. In
‘other instances, two PIM paris may be assembled afer
pressing. and then bonded into a one-piece part during
sintering,
P/M IS VERSATILE
The bosic versatility of P/M is applied in numerous
industries, including cutemotive, business machines,
cerospace, electrical and electronic equipment, small
‘and major oppliances, agricultural and garden machi:
ery, off-highway equipment, sporting goods, hand and:
power tools. Thousands of different cost-saving reliable
PIM designs now serve these industries ina wide
range of engineering applications which fal into two
main groups. In one group ore pars which are very aif
ficult to make by any other production method, For
exemple, paris of dificul-to-fabricate materials such os
tungsten and molybdenum, or tungsten carbide, cannot
bbe made efficiently by any other process. Also, porous
borings. ters ond many hard and soft mognetic parts
cre exclisvely products of the PIMA process.
Another ond larger application group consists of com
ponents where P/M is an effective alternative to
machined parts, castings ond forgings (Figure 1). P/M.
technology hes also expended into precision hot forging
from sintered preforms, thus extending its capabilties to
providing P/M ports with inereosed strength, toughness
cond fatigue lif.
The following sections describe the PIM process,
materials, perlormance properties and design porame-
fers thot define the technology's capabilities and pro-
vide guidelines for development of a relicble, efficiently
produced port ADVANTAGES OF THE P/M PROCESS
Eliminates or minimizes machining
Eliminates or minimizes scrap,
‘Maintains close dimensional tolerances.
Permits a wide voriety of alloy systems
Produces good surface finishes.
Provides materials which may be heaMreated for
increased strength or increased weor resistance
* Provides controlled porosity for self-lubrication or
filtration,
Fociltates manufacture of complex or unique shopes
which would be impractical or impossible with other
metalworking processes
Provides excellent port-to-part reproducibility and
repeatability
Suited to moderate-to high volume component
production requirements,
Offers long-term performance rebcbilty in eritical
cepplications.
+ Cost eflective.
+ Energy or environmental efficient
FOR THE LATEST
AND MOST COMPLETE
INFORMATION how p/m parts are ma
8
Typical parts can be produced at rotes of several hun:
dred to thousonds per hour with the P/M process
Although normally associated with high volume proce
tion, P/M is also feasible for economic part production
in lower volumes. Also, extending tooling use to produce
more than one part, such as in varying thicknesses or a
common part with different size holes, will enhance the
low volume economic rattanale for PIM. Another con-
sideration is that the port design should take edvantage
of the ability of the PIM process to minimize secondary
processing operations in comparison with these require
iments if the part were to be produced by competitive
methods. When these factors are considered, P/M parts
can often offer cost and performance edvantages in
short pradkction runs.
BASIC P/M STEPS
The three basic steps for producing conventional parts
by the powder metcllurgy process are mixng, compoc!-
Ing ond sintering IFigure 2
ing-Elemental, portilly alloyed or preolloyed
metal powders are first mixed with lubricants or other
allay addtions to produce a homogeneous mixture of
Ingredients. These additives may help impart machin-
‘bility. wear resistance or lubricity 10 the base alloy
‘composition. The mixing may be done by either the
‘metal powder producer or the P/M parts manufacturer
Compacting-A coniroled amount of med powder
is automaticaly gravily-fed Into a precision die and is
compacted, usually at room temperature. af pressures as
low as 10 tons per sq. in. or as high os 60 or more fons
pet 5q, In. (13B to 827 MPal depending on the density
requirements of the part and the powder being
pressed. Normally, compacting pressures in the range
of 25-50 tons per sq, in. (345 to 690 MPa! are used,
Higher pressures limit tool life, especialy with thin or
fragile tool components
Compacting the loose powder produces a ‘green
compact” which, with conventional pressing techniques,
has the size and shape of the finished port when eject
ced from the die, ond sufficient strength for in-process
handling and transport fo a sintering furnace. Typical
compacting techniques use rigid dies set into special
mechanical or hydroulc presses.
Tool sets ate made of either hardened steel ondfor
corbides, and consist at least of a die body or mold, an
upper and lower punch and, in some cases, one or
‘more core rods, Die materials are selected to withstand
the high compaction pressures and abrasive character
istics of the metal powders,
The pressing cycle for producing a simple partis
shown in Figure 3. The die receives @ charge of mixed
powder, delivered to the cavity by o feeder shoe. The
Upper and lower punches compress the powder. The
volume of powder fed into the die is controlled by the
relotive postion of the lower punch in the dhe. After fille
ing, the feed shoe is withdrawn ond the upper and
lower punches compress the powder. When compaction
is completed the upper punch is withdrawn, relative
motion between the lower punch and die ejects the
pressed compact and the feeder shoe sides the piece
‘away from the die covily. The feeder shoe continues
forward ond refill the cavity with another charge of
powder ond the cycle automaticaly repeats.
This compacting cycle is typical. When more then one
pressing level is needed, however, os for excmple in
Figure 2 « The PIM Process making flanged shapes or cluster gears, multiple punch:
es with separote actions may be needed [Figure 4).
Holes in the direction of pressing can be molded by
Using additional core rods. Figure 5 shows o multilevel
PIN\ port and compacting press in the background,
‘More specialized compaction and alternate forming
methods are sometimes used, such as isostatic pressing,
extrusion and injection molding, Warm compaction of
ferrous powders, ot temperatures of 200-300 |95-
ISOC! is used to achieve higher densities and create on
iton-plostic composite with unique mognetic properties.
Sintering-h the typical sintering step. the green com-
pact, placed on a mesh belt, slowly moves through @
controlled-cimosphere fumace [Figure 61 The parts are
heated below the melting point of the bose metal, held
ot the sintering temperature, end then cooled. Bosicolly
«solid stale process, sintering transforms compacted
1 Oycle
2 charging
ting) die
with powdery
‘3Compaction
begins
Acompucron 4
si #4 TT
Figure 3 - Pressing cycle for 9 single level port
PIM Cluster Gear
(Dual Level)
uch
Core Rod.
Die.
=f he.
Figure 4 - P/tA tooling for 2 tworlevel port
Figure 6 - Sintering Ports entering furnace.
mechanical bonds between the powder particles into
metallurgical bonds. This provides the P/M pats xia:
1y functional properties. Typical sintering temperature
ranges are 1450-1550F (790-845'C) for bronze and
2050-2100F (1120-1150°C) for Ferrous alloys. Belt fur
nace cycles average 1-15 houts for small bronze bush
ings and 2-3 hours for average size ferrous ports.
Throughput vories with port size, belt width and speed,
reaching ¢s high as 1000 pound/hour (450 ke/howr) in
lorge furnaces.
Enhanced sintering of ferrous P/M is done at higher
femperaiures. on average 300 higher than conven
tional belt sintering, to provide increased mechonical
properties, superior soft magnetic parts and improved
stainless sige! materiols The sinfer-hardening process
sing @ controlled cooling rate in the cooling section of
the belt-sintering furnace, transforms the steel matrix of
«ferrous part to martensite, thereby eliminating the
need for 2 secondary hardening step.
PIMA ports ore generally ready for use afler sintering.
However. fo provide special properties, the parts can
be repressed, impregnated, machined, tumbled. ploted
or heat-trected. Rae M ACN C CONICS
Secondory Operation Typical Pars (Objectives
Repressing
Caring Al Dersiicoten, modfy surface shape (coming). dimensional conral
Sting Al Dimensional centro
Impregnation
oi Bearings ‘Moke bearings selflubricating
Resin Shuto! Inprove machinabily, Prepare surface fr plating wth ether matols
‘Seo pes gos er kqud tght. Provide lubrication,
Infiteation Ferrous lnprove strength seal ports gos or lui igh
Siucturl Prepare arface fr alarng wih ther metals Inprve duchy and
rmochinebiy
Heat Treating
Quench and Temper Fertous Shucturol Improve srength and hordes.
Steom ect Ferrous Icke srice herd ond wear resston!Inprve coroson resisonce
cand seal porosity
Mochining
Dill ond Top all To instal st screws or assembly fosters
Tring al NMochine to exact tolerances Feem undercuts or features not possible
wih compaction tootng
Mliog Al Form underuts oss
Grinding al Remove stock: make faces fat ond parca improve sure
fish and dinersiona oleronces,
Finishing
Debuting Al Remove shorp edges reloted to punch and de foaing
Burishing Ferrous Stucke Bal io roller bush for size contol and surface fish
Coating OI Dp Ferrous Corrosion resistence
Cooper, Nickel, Feros Corson resistence; oppecrence
Coctium, Zin
Chromium Plating
Weldng Ferrous Make esses from two or more pats.
(68 olem? min density
Block Ove Ferrous Corrosion resistonce, point bose
rea impregnoted
Mechanical Surface al Cleanlinprove srfoces
Treiman
Gloss Beading
Wire Brash
Sanding. Turdling!
Veotry Finishing
‘Shot Peering Ferrous Sct Improve surface fotgue He
Forgings
Folrone Powe Motlinay Deen Maal ‘SECONDARY OPERATIONS
The controlled porosity in P/M parts permits their
impregnation with ol or @ resin, [igure 7) Also, with
suitable compaction techniques, porosity con vary in dif-
ferent areas of the P/M part
Ollsinpregnoted P/M beorings have been used in
‘automobiles since the late 1920s. Conventional P/M,
becrings con absorb from 12 to 30% by volume of
generally, addiive-fee, non-cutomotive engines oil
lnjoregnation is achieved by sooking the parts in heat
ced oil, or by vacuum techniques. When friction heats
the por, the oil expands and flows to the beoring sur
face On cooling, he oil returns into the metal pores
by copillary action
The some porosity, however which is so beneticial for
cil mpregnation con be quite detrimental to @ port
undergoing some secondary operations. Molten sats,
cutting fluids, cleaning and plating solutions can be
tropped in the pores, hereby leading to later corrosion
or unsightly “bleed-out’. Farts ore typically pre-imprege
noted with @ resin prior to ony such exposure to fluids
‘r solutions. Immersion in molten salts is discouraged
altogether
Burr relief slots, [Figure 8), are practical modifications
to inside diameters of parts with hubs being drilled anc!
topped to receive set screws, Use of such a slot or
recess provides room for the machining burr while stil
keeping it away from the shaft on which the port is
mounted.
Ferrous P/M ports con be succassllly welded or
brazed. Most conventional welding methods (TIG,
MIG, electron beom. resistance, friction, laser or
copacitve discharge] are applicable. Welding perfor-
mance is determined mainly by part densty,olloy com
postion, proper joint design ond elimination of contami
rants (oils, Iericonts, coolants, elc |. Furnace brazing,
Using special copper brazing alloys designed for PIMA
parts, con be completed during the sintering process
Fgxe 9.
Figure 7 - O11 impregnetion
Figure 8 - Gur colt slot
Figure 9 - Furnace AAs precision engineered materials « diverse group of
metal powders is avalable for « wide range of PIN
products, Generally, powder mixes for compacting are
prepared from three powder types, The fist is admixed
where elemental alloying powders such as copper nick-
el, graphite and tin ore added to base element pow-
ders such os iron or copper Partially alloyed powder is
composed of two or more elements where the alloying
tadatives ore diffusion bonded to the base powder dur-
ing the powder monufacturing process. These powers
Ose nmr ane Cee
cxeduce @ helerogencous micrastructure with good
dimensional control and excellent as-sintered mechani
cal properties. Preclloyed powders, on the other hand
ore stomized from alloyed furnace melts: each powder
particle has the some nominal composition throughout
Prealloyed powders yield homogeneous phase con:
stituents in the microstructure.
For a brief overview showing the scope of conven:
tional P/M metericls, four tables are given
FERROUS STRUCTURAL PARTS
Material Density glem? Tensile Strength? ‘Comments
10°psi (MPa)
Carbon Steel (-0008 69 540970 « ‘Chen con ele
OBkce *+* ANNE 25 5501 +
Copper Steel- £C-0208 7 solaioe Good stored strancth
ZAC. 08%ce mE Sn 85 [5901 =
Nickel Steel-FX.0205 69 soca Good Keo rected
FANOStce mE SAAR 120 18201 + strength poet ene
Infitrated Steel - Fx-1008 73 87 woos Good srenath
105C0 08%ee Ram ERRORS |20 (230) ++ closed flora poresy
Low Alloy Steel, Fl-aé05 695 5 4ool* Good horde,
prealloyed O54 cc eonRscresrer m= 1301900 conssency net
Nie" recent,
Low alloy steel, Fin-4205 705 731800) ocd ser
Ni'Mo= 1SEN, O58 ce aa SRNR 150110301 ¥# bah sere and bot
treted
Diffusion Fo.040s, 7.05 10317101 Very geod
Aleyed sete 05% ANNE 140970) $¢ —critore skonghh
iC Mo
Sinter Fic-4608 700 \o0(690) High hardness ond stenath
Hardened Steel 2% Cu 08% ce frm stering
Ni Me prealoy -
Sloinloss steels - 55-434 N2 ELON 60 (410) Good emen restnes,
234 sonss sppecronce
SS.316N2 6s souioie
316 sans
SS-410%T ES NNN 10 1720)»
410torles
+ Relerence: MPF Standard 35, Material Stondords For PIM Stet
» Aesntered
‘Host Weoted
‘6 Combined carbon
tol Pols. Srenath and denay are owen os typical vals, SOFT MAGNETIC PARTS
Material Dens ‘Mag. Induction Coercive Force
= kor T Oe. Alm
ron, lower density 66 100 10 2000 20 160
Iron, high densty| 72 130 3 3500 7 136
Phosphorous iron O458P 7.1 120 12 3500 15 120
Phosphorous iron O.ASRP 72 130 13 000 12 %
Silicon ron 3% Si 72 130 13 6000 10 80
Nickel iron 5O% Ni 74 120 12 20000 0.25 2
410 Stainless Steel 71 105 os 1750 20 140.
"Magione Feld 15 cero
NONFERROUS PARTS
Material Usage and Characteristics
Copper Electrical parts
Bross Electrical ports. Applications requiring goed corrosion resistance. appearance and ductility
CZ-1000, 10% zine
CZ-3000, 30% zine
Nickel siver
CNZ-1818, 18% nickel, 18% zine
Aluminuen ello
Ticniam
tensile strength 34 x 10%)
Improved corrosion resistance, toughness
Good sirengthinass rato. cortasion resstonce:
‘SELF-LUBRICATING BEARINGS
tensile strength 20 X 103 psi 140 MPa}
MPo|
® 7.9 gfem*, tensle strength 34 x 1D%psi (230 MPa)
Good corrosion resstonce, lightweight, good electri
ical and thermal conductivity
Material Density, glem? Oil Content, % Vel. K Strength, psi (MPa)
~CT-1000 60-64 24 19000 {130)
CIG-1001 64-68 7 2300001160)
Diluted Bronze
FCTG-3604 60-64 7 22000150)
lron Graphite
FG-0303 56-60 18 10.000 70) 10
engineering properties
A wide range of powder metallurgy moterials, meet-
ing the design requirements of particular applications
‘fe avalble. The following property descriptions
include those related to density, mechanical characteris
tics and physical properties,
Density—Most properties of «PIM part are closely
reloted to its final density. This densiy is the mass per
Unit volume of the part expressed in grams per cubic
centimeter {gfem']. Normally, the density of structural
pats is reported on a dry unimpregnated basis, while
the density of bearings is reported on « fully oil impreg-
nated basis, Densiy is most commonly determined using
the method given in ANPIF Standarel 42**
Density is also expressed os relative density, which is
defined os the ratio of a PIM par's density to thot of
tts pore-free equivalent. In practice, P/M parts less than
75% of relative density are considered to be low dens
ty: those above 9OR ore high density: and those in
between these two ranges are considered as medium
densiy. In general, sruclural ports have relative densi-
ties ranging from 80% to cbove 95%. Forgings and HP
products often exceed 99% Many sell-lubricating bear-
ings have relative densities of the order of 75% and fi
ter parts usualy have relative densities of SO%
Porosity—Porost isthe percentage of void volume in
© part. Iris the converse of densily. A part which has
85% relative density will hove 15% porosity. Porosity in
PIM ports can be present asa nelwork of infercon-
nected pores that extend fo the surface like @ sponge
oF a5 a number of closed holes within the part
Interconnected poresly is important to the performance
of self-kbricating bearings and is port of the specifica
tion for these types of materials
Porosity is @ controllable function of the raw material
cond processing techniques. Parts can be procuced
either with uniform porosity or with variations in porosity
land density] from one section to another to provide
dierent properties. For exomple, porls con be made
self-lubricating in one aree and dense and strong in
other areas.
Permeability—The obiliy to poss fluids oF gas os, for
example, in filers is cnother unique property thal can
be designed ino P/M products. Depending on the
forming and sintering techniques, PIM part can pro-
‘valable Fam the Nica Pow nas FadoraionPIRCSoN
New lore, CB540-6002 (rel 09-452.7700 fox 609-987-8523
espns! Ema lamers
vide permedbilty canging from highly restricted fo open
flow. The port can be produced with permeabilties
which will separate materials selectively; cffuse the
flow of gases or lquids: regulate flow or pressure drop
in supply lines: or act os flame arrestors by cooling
goses below combustion temperatures. iters can be
produced in olmost any configuration, including sheets
nd tubes
MECHANICAL PROPERTIES
As with wrought and cost metals, chemical compost
tion of PIM\ parts srongly influences the mechanical
properties In P/M parts, however, properties ore
dependent on additional factors, such as: density; part-
cle size: pore size, shape and distribution; and extent of
sintering
For this reason, mechanical property data are often
given in graphs showing the relationship belween the
property and the density or percent of relate clnsiy)
The graphs or chorts shown, Figures 10, Tl & 12. repre-
sent typical volues ond the rend of properties versus
densily from test specimens confarming to chemical and
density requirements found in MPIF Standard 35,
‘Materials Stondords for P/M Structural Parts [refer to this
standard for a complete ising of mechanical properties).
Test data obtained en standard specimens do not
necessarily accurately represent the performance of an
ccclucl port. Test specimen dato should be considered
only as an approximate evaluation of part performance
‘More commonly, proof tests on actual parts are used in
test configurations mutually agreed upon by users ond
manufacturers
Strength Properties-Figure 10 shows ultimate tensile
‘ond yield strengths of a 2% nickel and O.B% carbon,
pressed and sintered P/M steel as a function of density
Yield sirength, generally 62 to 98% of ultimate strength,
is closer to the tensile strength than with wrought met-
ols Also, the yield strength of many P/M materials, por-
ticularly stainless steels, may be higher than the wrought
forms.
Figute TI shows impact eneray of two P/M nickel steels
18.0 function of density, with impact energy rising signif
cantly at higher densities ond lower carbon contents
Duetility-Ducilty, the amount af plastic deformation
prior to tensile fracture, is relatively lowe in PIM materi-
‘ls, chiefly due to the presence of pores Duectilly as o
function of densty is ilusrated in Figure 12. Elongation 6s 70 78
Density, gfem®
strength and 0.2% yield point
0208 (2% Ni 0.8% C),as-Sintored
Tensile and yield strength vs density.
X-= FN-0205 (2% Ni, 0.5% C)
‘= EN.0208 (2% Ni 0.8% C)
40
35; 0
20
15
10 40
5
20| 40
7 30
20
es 70 74
Density, giem?
Unnotched Charpy impact Energy
as Sintored, Nick Stools
Charpy impoct energy vs desnity
Figure 11
| FN-0205, (2% Ni, 0.5% )
Figure 12 - Elongation vs density
is generally less than 10% for ferrous materials. For
‘some P/M brasses and stainless steels, however, elon-
gations range from 15 to 25%. Ductility of most P/M.
moteriols can be increased considerably by hot or cold
repressing followed by resintering.
Hardness (Apparent)-Because of differences in
structure, gross indentation hardness values of wrought
metals and P/M ports cannat be compared directly.
Hardness of o P/M part, when obtained using a stan-
dard tester and scale, is referred to es “apparent hard-
ness’, combination of the powder particle hardness
‘ond porosity [See MPIF Standard 43). Figure 13 shows
how on indenter can compress the suface between por-
ticles or displace powder particles in low-denstly parts
Wrought Stee! PM Material
Figure 13 - Hordness indenter penetrates deeper in P/M.
material becouse of lawer densty
Particle Hardness—Sometimes called metrix hardiness,
It ts measured by a microhardness test, such as Knoop
cor Vickers. Here, the purpose Is fo measure actual metal
hardness, unaffected by any porosity. Microhardness
tests and evaluation of heat treated cose depths ore
discussed in detail in MPIF Standards 51 and 52.
PHYSICAL PROPERTIES
Corrosion Resistance-Porosty in PIN\ parts signi=
contly affects corrosion resistance due to possible
eeniropmen! of corrosive media. Higher density improves
Corrosion resistance, as it does most other properties.
Stainless steel PIM parts have relatively good corrosion
resistence in the atmosphere and in weak acids
Nonferrous P/M materials have corrosion-resistont
properties similar to the wraught forms
Surface FinishExcellent surface finish isan inherent
feature of P/M parts. The overall smoothness and sur-
face reflectivity depend on density, tool finish ond sec-
‘ondary operations. Conventional proflometer readings
RMS) take info account the peoks and valleys of
machined surfaces, while P/M\ parls have « series of
very smooth surfaces which ore interrupted with cores
of varying sizes, A chisel point stylus should be subsiut
eed for the more typical radius stylus when mecsuring
the surface finish of P/M parts with a profilometer
Figure 14). Effective surface finish of PIM parts com
pares favorably with ground or ground-and-polished
Chisel Stylus For Surface Measurement
‘The stylus is chisel shaped and has
{a standard radius onthe edge 1.27 mm
(0.080 in) wige so that itwit not crop
Inothe porosity of the PIM surface
And give 8 false reading by mea-
uring he eaves.
a Sitee
Etfect Of Chisel And Cone Styli On
‘An As-Sized P/M Surface,
Figure 14 - Surface finish measurement using o chisel siyhis
WL 12
surfaces of wrought and cost components. Surface
smoothness con be further improved by secondary
operations such as repressing, honing, burishing, or
grinding
Sound Damping-The porous nature of P/M ports
provides good sound damping. Ringing. common with
wrought steel gears and other parts. is reduced due to
the controllable density in P/M products, This is on
important benefit in business machines, air-conditioning
blowers, and similar products where quiet operation is,
highly desirable, Domping characteristics ean be further
improved by inillrtion or impregnation with sound
domping materials. The controllable density of P/M
parts is also used to dissisate and muffle noise of air-
driven tools
Hardenability—The depth of hardening achievable in
steel alloys is known as hardenablty. The higher the
hardenabilty rating the more hordenoble the steel.
Hardenabilty dota is provided in MPIF Standard 35
Material Stondards for PIM Structural Parts**
* guolble Won fe Mol Powder dries Federaon rca
Now Jey, OBS40-6682 ek 009-852-7700, fox 609-487-8529
vwinanatarg | Eel: fmt og SSC Im Nt
The PIM process, smllr fo olher port fabrication
methods, hes its own set of design guidelines for pro-
ducing well engineered, economical products. The por
Ticular ospects and requirements of P/M production
should be considered. Design advantages then can be
gained that ore unique to the P/M process, and is limi-
fotions wil have been taken into account.
Designing for powder metallurgy recuires close coop-
eration between the port user. or buyer, ond the pro~
ducer especially in the initial design stoges. The P/M
part should be designed in the context of the whale
cssembly, with the porls manufacturer being informed
throughout the entire process. An improved, lower-cost
PIN\ pat often can be achieved through small changes
in on assembly, Frequently, early designer-manufacturer
inleraction results in an expansion of the PIM concept
thot can simply the design and reduce cos.
For greater depth and detail, designers are encour-
‘ged to sludy the MPIF Powder Metallurgy Design
‘Manual
TOOLING CONSIDERATIONS
The PIM part design and the complexity of tooling
used to produce it are closely related
Two major factors in the compacting operation infly-
lence or control part design: the flow behavior of mets!
powders and the pressing action, Metal powders do
rot flow hydraulically becouse of friction between the
particles and the dies. The design, therefore, should
ensure adequate powder distribution within the die
cavity to cllow satisfactory compaction. Because metal
powders also have limited lateral flaw, there are some
limitotions on the contours that con be produced,
SIZES AND SHAPES
Press Capacity Round Part,
(tons) Max. Diameter (in)
=30 15 [410 MPol compaction
25 103 (262 mm}
200 291739 mm)
500, 40111171 en
Part Size- Wider parts cre possible if perpendiculor
dimensions are reduced so that the moximum projected
trea is not exceeded. At higher press tonnages, 40 tsi
(560 MPa), for exomple, the projected diefpunch crea
will shrink, ond a 200 ton press will have @ maximum
round die diameter of 252 in (640 mm),
+ Since compaction occurs in the vertical direction
using only top and bottom motions, part lengths in
the pressing direction ore limited
+ Compression ratio, the ratlo of the height of the
loose powder filling the die 4o that of the compact-
ed port, also tends to limit vertical par! lengths
Shapes
+ Shapes with uniform dimensions in the pressing
direction are easiest to produce and eject from the
press
+ Cams, gears and sprockels ore ready made.
+ Thin walls ond projections may require fragile tools:
consider corefuly
* Face forms on upper or lower punches can provide
bosses, pads, lettering, countersinks, etc.
Multi-level Shapes
+ More complex, multi-motion tooling is required to
maintain consistent density throughout parts with
more than one level.
+ Both mechanical and hydraulic presses are aveil-
able for making pars with five or more levels
+ Ports weighing © few grams to 26 pounds |118 ka)
or more ore possible [Figure 15)
Figure 15 - Variety of P/M parts
7 avalale hon he Maal Powder Fis Federation, Wnevion
Now Jersey 08540:6802/ fel: 609-4527700, for 609-987-8523
vwerapg Ema: Foon ong
13, 14
DESIGN DETAILS
Holes
+ Holes in the pressing direction can be round
D-shaped, include keyways, splines, etc. Tooling
members which create holes are called core rods
+ The core rods must remain straight andl not buckle
dining compaction, or ejection ond dimensional
problems may result.
* Lightening holes ore frequently added to large parts
to reduce projected pressing oreo, thus making
ports easier to press and lower in weight
'* Blind holes, blind steps in holes and tapered holes
core recdlly produced
+ Side holes have to be produced offer o sintering
‘operation, usually by machining.
Wall Thickness
+ Die ils clkimportant; do not mke walls thinner
than 0.060 inch |1.52 mm} as @ general rule.
* Long, thin walls result in fragile tooling and parts
with endencies loward variations in density
‘+ Where the ratio of length-to-wall thickness is as
high os 8 to | or more, special precautions must be
taken to achieve uniform fill, and variations in densi
ty ae unavoidable.
Flatness
+ Total measured flatness depends on port thickness
cond surface area
+ Thin ports tend to distort more than thick parts cur-
ing sintering or heat treatment
+ Repressing improves flatness.
+ Projection bosses are easier to bring to flat than
entire face areas
Tapers and Drafts—Draft is generally not required or
desired on sides of parts. While draft on outer sections
for ejection is sometimes helpful it demands careful tim-
ing of the tools and slower production rates,
Fillets and Radit~Generous fillet rad are most
desirable:
+ Tooling with such fillets is more economical, longer
sting
+ Ports mode with generous fllels are made more
ceosily ond more quickly
+ Parts made with fillets have grecter structural
integrity Figure 16)
‘Chamfers and Bevels—Chomfers rather thon rock.
‘ore necessary on part edges to prevent burring. For
‘example, on « bushing (Figure 17], 0 30-45) charnfer
cond 0.005 to OOIS inch (0.13 to 0.38 mm} Flot to
eliminate feather edges are the preferred procice.
Feather Edges
++
Original Design
GS ¢
Avoid narcow, deep
spines on tne part.
Proterred Design
fr
=0z0
‘A oundes corner gives batter powder
tow in die and gives part increased
‘strength anc eliminates stress
‘sors in tools ana pacts,
lOlo
Rounded corners permit uniform
powder flow in the die.
Figure 16
Figure 17 - Chomfers are preferred on port edges
Figure 18 - Chomfers in clearance Figure 19 - Countersink in clecrance,
Large ongle chamfers may be produced by bevels in
dies or core rods (Figure 18). Production rates would be
slowed with such looling because of the need for cou-
tion in preventing dle-fil and between-tool powder
wedging problems.
Countersinks—A countersink is @ chomfer around
hole far a screw or bolt head. When the countersink fs
formed by @ punch, « 0010 inch (0.25 mim) nominal flat
is essential for avoiding sharp, fragile edges on the
punch Figure 19),
Flanges—A comparatively small flange, step, or over-
hang con often be produced by machining a shelf or
step in the dia, Too large a flange causes ejection diffi-
cules Bottom flange edge ond juncture radi should be
generous
Bosses~Boss forming cavities may be located in
punch tools. Cowties may not be too deep in ration
to pert height (5% less] and drat angles should be at
least 12° per side to avoid sticking af the compacted
boss to the punch.
Hubs—Hubs, which are complementary part sections
to gears, sprockets, or cams, can be readily produced
by the PIM process. Remember to include © generous
radius between hub and flange section, and fo moxi-
mize space between hub O.D. and geor or sprocket
root diameters
Studs—While studs with dratted sides can be made
lke bosses, sometimes no draft is alowed or stud
heigh!-to-diometer ratio is relatively large. In that case.
tooling with additional punches is required. Always
consider the frogiliy of the green compact prior io
sintering
Slots and Grooves—Grooves can be pressed into
etther end of o port from projections on the punch face
‘with the following general imitations [Figute 20
+ Curved or semicircular grooves to @ maximum depth
of 20% of overall port lenath.
+ Rectangular grooves to o maximum depth of 15% of
‘overall part length. provided thot surfaces parallel
to the pressing direction have up to 12° draft ond
al comers are radiused.
Figure 20 - Semiciscular and rectangular grooves con be
pressed from o projection on the punch faces into either
tend of the component provided that the guidelines for
raft; height and radtus are Followed.
Deep. narrow slots and grooves require fragile tool
members and should be avaided,
Undercuts
+ Undercuts on the horizontal plane Iperpendicular to
pressing direction! cannot be made since they pre-
vvent part ejection from the die.
+ Annular grooves may be machined os @ secondory
‘operation (Figure 21)
+ On a part such as shown in Figure 22, where @
[uncture undercut is needed fo allow fi-up too
dead comer, an aliemotive approach is shown in
Figure 23.
Tolerances
The tolerances which can be held in the PIM pracess
compare favorably with other parts fabricating process:
5, Economically, olerances no closer than necessary
should be specified. The following table illistrates toler
tance characteristics of competitive near-net-shope
forming methods: (Die dimensions, unless stated! other
wise)
Figure 21- Anoular grooves cannot be molded. They can
be machined.
15 16
nn |
Cannot Do
Figure 22 - Undercuts conrot be formed except with
secondary machining,
Forming Typical Critical
Method Dimensional Dimensional
Tolerances (inJin)_ Tolerances (in.in)
Pi 0002 70001
PIM
(Secondary Forming) +0001 0.0005
Cold Formed 20010 0002
Hot Extrusion 20010 10003
Fine Blonking
{Single Lovell 010005 20.0002
Die Casing
‘Mognesium, Aluminum «0002 200015
Zine 20.0025 20001
Hot Closed Die
Forging
Conventional 2002 10015
Pith, perpendiclor
to press ons 200032 so0o2s"
PIM, poral
to press xis 10010 00005
Die patagine Wlaences wl be Fro
fhe above
* Future quenched fora. raha clang kr quenching ding
he rear! reste ce hot engig con hold ean ihr
toons
Producer concemns in holding P/M tolerances:
|. Whot is the relationship between sintering condi
tions end the metal powder used?
2. What is the lorgest dimension that must be held?
3, What tool wear will this metal powder couse when
compacting to the chosen green density?
Thee hes een
4, Assuming symmetrical part shape around an ID.
what run-out tolerance is required?
5. If ferrous parts, will hey be heat treated?
© Ave tolerances demanding enough to requite sizing?
Prototypes
Three prototyping oplions are commonly used
1. Machine from a PIMA blank. PIMA blanks, 0s
pressed and sinered or infitroted ore ovailable
from PIM parts manufacturers. Machining and fin-
Proterred
Figure 23. Con be formed ducing compacting,
ishing steps in fabricating the protatype part from
the blonk should maintain the surface finish and
porosity typical of the P/M part, The blank will be
Uniform in density and may not cccurctely repro
duce the density variation found in mult-level ports.
Evaluating several density levels is suggested
2, Press from a set of tools that contain certain
defined features (such as on ID spinel, sinter, and
then machine the remaining features lsuch as gear
teeth and a hub).
3. Press the entre part from a set of tools and sinter.
This option is viable when the part configuration is
relatively simple or where a large number of proto-
types is required. This option is the most costly ond
time consuming, but most reliable.
DESIGN OF TYPICAL PARTS
Gears are well sited to PIM production
+ Carbide dies provide long life and accuracy
+ Residual port porosity tends to dampen sound.
+ PIM gears can be made with blind comers, thus
eliminating the need for undercut relief
+ PIM gears con be combined with other contigura-
tions such os coms, ratchets, ether gears, and vari-
ous components
+ Helical gears are possible: copper inlitration is
sometimes used to improve teeth densities.
+ Since tooth shope is not © problem, true involule
gecrt forms are easier to produce than by other
fabrication methods
When designing PM gears:
+ Note that the center hole location relative to the
gear shape is affected by the running tolerances of
the various tool members. This makes it more dificult
to hold the close TI's obtainable with orbor cul
gears, and hubs or pinions that increase the number
of concenitic tool members increase the TIR toler-
‘once needed. TI's can be reduced by grinding
sgecr [D's true to the gear pitch diometer. + Asthe AGMA closs of gear increases, s0 does the:
cost of the gear because of the secondary operc:
tions required to meet the tighter tolerances
+ To avoid having very thin teal members, gear hubs
CF pinions should be located as far as possible from
gear root diameters. See Figure 24
Coms are also well suited to P/M:
+ Process provides excellent surface finish ond port-to-
part consistency.
+ The natural finish of self-lubricating P/M com will
‘often outwear a ground cam surface
* For radial coms, the com shape fs formed in the die;
for face cams the shape is formed in the punch
foces.
Assemblies
+ Two or more P/M parts offen can be joined to form
© unit that is difficult, if not impossible, to make os @
single structure
+ Capitalizing on PIM flexblity, ts feosble to moke
ossemblies of very different materials: a bronze
bearing in o ferrous structural part, for example, or
heat-treated part with « non-heot-treoted par.
+ PiMA ports can be joined by conventional methods
such as staking, press-fiting, brazing, soldering,
welding, epoxying. riveting, bolting, and olso by sin-
tering together materials of appropriately different
size chonge characteristics.
+ Copper infitration during sintering can be used to
bond steel parts.
Bearings
+ Bearings ore @ natural product for P/M because of
its conttolled porosity and the resulting self-con
tained lubrication
Plain beorings, flanged bearings, soherical beorings
‘and thrust washers ore commonly produced,
+ The operating environment should be corefully con-
sidered: external lubrication, cooling, hardened or
chromium-ploted shafts fend fo increase permissible
loads. Repeated stor-stop operation, oscilatory or
reciprocating mation, high speeds, shock loads and
temperature extremes tend to decrease permissible
loads
For detailed information on permissible loads, press
fits ond tolerances, see the engineering section in
PIF Stondard 35, Materials Standards for PIM
SelF-Lubricating Bearings.
No
Figure 24 - Hubs should be locoted ax for as possible
from gear’ reot diameter
17 18
The powder metallurgy process hos expanded into the
production of near-fully dense materials and parts, wth
residual porosity offen being less than 1%. These
processes use diflerent compacting methods and may
involve greater emphasis on high alloy materials and
enhanced sintering techniques. Some of the specialized
processes and alloys involved in this new and growing
technology follow.
POWDER FORGING
Powder metaluray steel components with wrought
properties are currently in moss production. One popu:
lor material is type 4600 steel with varying carbon lev
els and conventional heat-treatment when necessary.
Several manufacturers within the PIN\ industry produce
millions of powder forged [P/F) paris annually, primarily
for automotive original equipment.
The basic process common to most powder forged
systems is to manufacture o “green” compact called o
“preform, sinter and then resirike/forge the “preform” to
the required final density
Two PIF ports produced are shown in Figures 25 and
2; Figure 27 illustrates the strength and ductility
advantages of powder forged 4640,
ISOSTATIC PRESSING:
isostatic pressing generally is used fo produce lorge
PIN\ parts to near-net sizes and shapes of varied com
plexi. Unike conventional press compaction, isostatic
pressing Is performed in o pressurized fluid such as cl
gos, or water. A flexible membrane or hermetic contain-
‘er surrounds the powder mass and provides a pressure
differential between its contents and the pressurizing
medium. The concept is shown schematically in Figure
28. A typical product made by this process is illustrated
in Figure 29.
Among the benefits of isostatic pressing are:
+ Complex shape capability.
'* Minimized expensive powder input.
+ Applicability to dificul-lo-compact materials,
+ Uniform density and properties.
Cold Isostatic Pressing (CIP)—Cold or room tempero~
ture compaction is carried out in liquid systems at pres-
sure commonly reaching 60,000 psi (414 MPa). Metal
powder is packed into complex-shaped rubber or elas-
tomeric molds before compacting. Free of die frictional
Figure 25 Powder forged (P/F) automotive connecting
rods.
Figure 26 - Ho! forged inner race,
40
Duet
Figure 27 - Tensile properties vs relative densily Isostalic Pressure
‘Shape of
Completed
Part
Figure 28 - \sestatic compacting.
forces, the powder compact reaches a higher ond
‘mote uniform density than would be obtained using
cold die compaction ot the some pressure. Powders
with spherical or rounded particles ore not cold com-
pacted becouse of their inabilly 10 form a sound or
strong green body. Sintering con be performed by any
of the conventional processes
Hot Isostatic Pressing (HIP)—Hot isostatic processing
is performed in a gaseous (inert argon or helium) ctmos-
phere contained within the pressure vessel; usually, the
goseous atmosphere os well as the part to be pressed
are heated by 0 furnace within the vessel
‘Common pressure levels extend upward to 15,000 psi
(100 Mo}, combined with temperatures to about
23007 (1250'C), Processing volumes currently reach to
Sift (15 m) diameter by 10 ft. (3.0 ml long, Higher
Figure 29 - Port made via cold isostatic compacting.
pressures ond temperatures are in use but with consid
erably reduced work volumes,
The powder to be HiPed is hermetically sealed. usual-
ly within a metal or gloss container or envelope which
deforms plastically at elevated temperatures. Prior to
seoling, the container Is evacuated fo eliminate residual
‘gases in the powder mass,
In contrast to the cold isostatic pressing process, the
hot process can readily employ powders with spherical
‘or non-interlocking particles, The powder is simply
poured in and vibration packed into a container of
desired shape, the powder mass is then simultaneously
compacted and sintered during the HIP process.
Denstication to near full densiy is achievable with
most materials The resulting mechanical properties ore
equivalent to wrought parts in a similar condition. In.
some moterias, the properties of the HIP product are
superior because of reduced anisotropy
Depending on the material being compacted, removal
of the HIP container is achieved by chemical leaching,
machining or other mechanical methods. As with cold
isostatic pressing. mandrels con form internal contours,
swith porting agents generally used fo prevent bonding
Dilferential thermal contraction eases mandrel removal
for simple, regular shapes. Mandrels with locking-in
features ore removable by methods used for confainer
removal
‘METAL INJECTION MOLDING (MIM)
‘Metal injection molding offers ¢ manufacturing capa
bilty for producing complex shaped parts in large
quantities. The process utlizes fne metal powders, typi-
cally less than 20 micrometers, which axe infimotely
rmixed with various thermoplastics, waxes and other
ingredients In contrast fo conventional powder metol
lurgy. these polymeric binder materials may comprise os
much os 40 volume percent of the mture. The resulting
feedstock is granulated and can then be fed into a
conventional injection molding machine. Multiple cavity
tooling is commonly employed. Mest, but not cll, ofthe
binder is then removed from the molded [green| com
pponents by thermal or solvent processing, or a combi-
raalion of both, The exact method chosen is dependent
Upon the binders used for molaing and the cross sec-
ions of the part. Following binder removal, parts ore
sintered in ether olmasphere or vacuum, during which
the remaining traces of binder are removed. Sintering
temperatures are usually in excess of 2300 (126°C)
Final relative densities are generally greater than 96%
with inter-connected porosity less than 0.2%
Parts weighing up to 250 grams are commonly pro=
duced (Figures 30 ond 31}, Cross sections ore generally
less than 0.250 inches 16.35 mm). However parts are
not restricted fo this combination of massicross section
19 20
Figure 31 Pivotal laproscopic surgical scissors with heli
cal gear
‘ond lorger parts are in production. Processing is nor-
mally to « tolerance of #0.3-0.5%, although specific
dimensions may be held as close os 201%, Due to the
use of fine powders and! low porosity, MIM products
have typical surfoce finishes of 32 RAAS (0.8 micro
meters). Common secandry operations, such os plating
oF hect irecting, are offen employed Since intercon
nected porosty isso lew. parts do not have to be resin
impregnated for plating and close contral over case
depth is possible in carburizing
The injection molding process eliminates the restriction
of straight sided components required when parts are
injected from o dle, ond offers opportinities for external
undercuts end threads. A wide variety of alloys can be
processed. including alloy steels, stainless steels soft
mognetic clloys and tungsten carbide. Material stan-
dards are avciloble in Stondord 35, Materials
Standords for Metal Injection Molded Ports, published
by MPIE
Process details
+ Powder sizes are fine, usually less thon 20
micrometers
+ Low injection pressure, generally less than 10.000
psi [70 MP)
+ low mokling temperature, approxmotely 300
(47),
+ Shrinkage, molded part to finished size. is typically
20%
+ Final part densities are usually greater than 96% of
the pore-fee densly
+ Ductlty is exceptionally high with elongation values
of 30% o higher
SPRAY FORMING
Spray forming is © process used to produce semi-fin-
ished mill products in the form of billets, tubes and
sheet/plate. Unlike conventional PIM, MIM. or PIF pro
cessing, spray forming is not used to fobricate individval
net shape components. The process consists of sequen
ficl stages of liguid metal atomization and droplet con-
solidation to produce @ necr-net shape product. The os-
sproyed material is close to full density with « fin,
equiaxed grain structure. Mechanical properties mest
or exceed those of ingot processed alloys. The process
is known for its high rate of metal depostion, typically
in the range 0.5-50 pound/second. Commercial pro=
cessing includes alloy steels, stainless steels, tool steels,
superalloys, aluminum and copper base olloys. An
example of a superalloy spray formed tube is shown in
Figure 32.
Figure 32 - Spray tomized tubes of IN625, ‘SPECIALTY MATERIALS
‘SUPERALLOYS
The use of high alloy P/M materials, notably superol
loys, is most common in the production of near-net
shapes ond forging preforms for aircraft lrbine
engines Economic benefis have been the prime driving
force in the use of PIMA for the manufacture of these
high cost alloys.
These superalloys are processed from highly-con-
trolled. metalluraically clean powders produced by inert
‘905 otomization methods that minimize surface oxida
tion during processing. After powder screening ond
cleaning the powder is compacted using hot isostatic
processing. Thermomechemical processing may be per
formed to enhance mechanical properties or microstruc
ture, Hol extrusion of the ctomized powder is an cller-
rote consclidation method,
PIN\ processing offers the advantages of « homoge-
neous microsiucture and near-net shape configuration
llower cost) As @ result ever 10,000,000 pounds of
PIM\ superalloy components are new flying in both mile
tory ond commercial aircraft engines.
TOOL STEELS
High performance tool steels and high speed steels
are produced In mill shapes using P/M process tech-
niques,
Advantages for PIM tools steels
+ Finer grain structures
+ Improved homogeneity and distribution of sec:
ondary and carbide phases
+ Elimination of secondary stringers.
+ Less distortion in heot treatment.
+ Improved grindabitty.
+ Greater wear resistance
+ Improved toughness and fracture strength.
Hot isostatic pressing (HIP) hos also been used in the
commercial production of P/M tool steels to near-net
tool shapes. such as hobs ond shoper cutters. Tool steel
parts con olso be made by conventional cold compact-
ing end high temperature sintering
REFRACTORY METALS
The refractory metals, alloys ond composites are pro-
duced using non-fusion, powder metallurgy techniques.
Products include tungsten lamp filaments, tantalum
Capacitors, molybdenum heating elements, tungsten-
copper composite heat sinks, ond tungsten-siver com-
posite circuit breaker contacts. The tungsten-based
“heavy alloys’ llungsten plus liquid phase sintering ids)
cre used for radiation absorption, gyroscope weights
‘and kinetic energy penetrators.
‘BERYLLIUM
The PIM processing of beryllium starts with cold iso-
stotic pressing followed by hot pressing or a hot forging
€or extrusion step. Sometimes hot isostatic pressing fs
substituted for the hot pressing step. Ove to its light
‘weight beryllum is used mainly for cirraft and cero-
space products,
TITANIUM
The use of P/M titanium metal and its alloys continues
to inctease since P/M provides « near-net shape prod-
ct os compared fo more expensive cast, forged ond
machined processing, Depending on the application
‘and production quantities titanium P/M products are
processed either by conventional press ond sinter tach:
niques or hot isostatic pressing. The latier exceeds the
minimum wrought alloy specifications, Product applica
tions include aerospace/aircrafi components, sporting
goods, chemical processing equipment and biomedical
systems
METAL MATRIX COMPOSITIONS (MMC)
Powder metal processing has been successtully
applied to a verity of metal matrix composites, the
‘most populer being cluminum-silicon corbide particulate
reinforced materials. These composites offer high stif-
ness (modulus), reduced thermal coeflicient of expansion
with litle offect on thermal conductivity or density
These Al-SiC composites are being used for their struc-
tural sifness and strength in aircraft and sporting good
products, os well os electronic thermal management
applications as heat sinks. Manufacturing techniques.
require cold isostatic pressing fo consolidate the pow-
ders followed by hot extrusion or hot forging to full
density
2 22
PIM parts are used in many products such as automo-
biles and trucks, home eppliances. power tools ond
hardware, riding lawn mowers and farmiof-rood
equipment, business machines and sporting goods
The overage North American passenger car contains
‘mote than 30 pounds (186 kgl of PIM, parts, which
opercie in the engine, transmission, slgering, brake ond
suspension systems. Automotive companies project P/M
part usage to approach 50 pounds (227 kg in the
near future
Power transmissions of all types are “home” to P/M.
Firearms have long been o fertile matket. not exclusively
in the group of paris \sear notch, trigger hammer, etc
which octualy tes the piece, Lock parts in both bross
and stainless steel materials are popular. Pollution con-
Figure 33 - Pi! gor's and products find mony uses
EIEN TE TCS
trol systems, exhaust systems andl ant-dock broking com
ponents consume milions of parts annually
Couplings, electrical relays with soft magnetic parts,
speed controls, printing hardware for computer systems
all contribute to the demand for P/M. Surgical implants
cond sophisticated medicol instruments ore a growing
‘market. Tools of all kinds, including fooling stock for
Compaction of P/M, continue to increase in use.
Whenever machining makes up « large port of prod-
Uct cost, P/M should be considered, within reasonable
sizes, of course.
For actual cose studies of successful applications of
PIM, the reader is referred to the MPIF "Powder
‘Metallurgy Design Manual The importance of discussing the port application with
con MPIF member P/M parts manulecturer can not be
overstated. Its the best way to take advantage of the
lotest techniques in ¢ ropidly growing industry, PIM is 0
high volume industry which can provide meaningful cost
reductions combined with high quality.
When requesting ¢ quotation, occurale part perfor
mance specifications must be provided. Refer to the
‘Metal Powder Industries Federation Stondard 35,
‘Materials Standards for PIM Structural Pars, for prop-
erties and specifications. In describing a part, stress
function end enticl requirements for satisfactory ser-
vice. For optimum results and efficiencies give the PIMA
parts manufacturer the widest possbe latitude in speci
fying material, design, physical charactoristics, dimen-
sional tolerances, eic. Widely diflering costs may result
from varying quality levels, change in tolerances or
design, oF failure to specify minimum properties. There
may be more than one MPIF material that can satisy’
the requirements
Typical information needed includes the following:
1. Order quantities which include intial needs ond a
future demand forecast, This enables the mos! eco-
nomial approach to cos's, manufacturing integra-
tion and delivery,
2. Detoiled crawings of the port and any assembly
ckawings. Actual samples or prototypes would be
helpful. Transmit any information such as knowledge
(of materials that have worked well in the application.
3. Can port design be modified without affecting
function? If so, where?’
4, Wil the PIM port replace one currently in produc
tion, oF is this & new application? Is the application
miltory, aerospace, medical, ee?
5. Actual service conditions: heat, moisture, impact
corrosiveness, el.
6, Necessary physical, mechanical, corrosion resis:
tance or special properties (lensile, elongation,
hardhess, flatness, conductivity, impact eneray,
fatigue sirength, leak tightness, et]
7. The finish required {plating, oxide coating, surface
fish).
8 If ony machining or secondary operations are
‘required, will they be performed by the PIM supplier?
9. For bearings: load, shalt material ond finish, speed,
service conditions and diameter should be noted.
For gears, specific dota ore required: a] number of
teeth, b} diametral pitch, <) pressure angle, d) measure-
how to specify p/m parts
ment over wires | tooth thickness, fl toot and tip
radius. g) helix angle and hand, h) AGMA quality class
il mating geor dota and nominal center distonce,
Inspection requirements-runout, pitch, protle and lead
tolerance, or footh-to-teoth, lotal composite tolerance
end testing radies.
Tools for each PIM part are custom designed and
developed speciically for that part, The expense of the
fooling may justly the more economicol approach of
initially testing prototypes.
The quality level end inspection techniques required
contribute fo the cost of @ P/M part, Programs such as
SPC and ISO 9000, for example, should be thoroughly
discussed and specified by the purchaser ond manulac-
turer prior to submission of a quotation
Fort producers are anxious fo keep current of potential
PIM customers well informed obout their technology
