Materi Minggu-9
POWDER METALLURGY
Mata Kuliah : Proses Manufaktur
Dosen : Idad S Haq
Prog. Studi : Teknik Industri (S-1)
Fakultas Teknik,
Universitas Widyatama 2017 1
Powder Metallurgy
Chapter 16
Manufacturing Processes, MET1311
Dr Simin Nasseri
Southern Polytechnic State University
Chapter 16 2
POWDER METALLURGY
1. The Characterization of Engineering Powders
2. Production of Metallic Powders
3. Conventional Pressing and Sintering
4. Alternative Pressing and Sintering Techniques
5. Materials and Products for PM
6. Design Considerations in Powder Metallurgy
Manufacturing Processes
Prof Simin Nasseri Chapter 16 3
Powder Metallurgy (PM)
Metal processing technology in which parts are
produced from metallic powders
PM parts can be mass produced to net shape or
Modern near net shape, eliminating or reducing the need
powder for subsequent machining
metallurgy
dates only Certain metals that are difficult to fabricate by
back to the other methods can be shaped by PM
early 1800
Tungsten filaments for lamp bulbs are made
by PM
PM process wastes very little material - ~ 97% of
starting powders are converted to product
PM parts can be made with a specified level of
porosity, to produce porous metal parts
Examples: filters, oil-impregnated bearings
and gears
Manufacturing Processes
Prof Simin Nasseri Chapter 16 4
Limitations and Disadvantages
High tooling and equipment costs
Metallic powders are expensive
Problems in storing and handling metal
powders
Degradation over time, fire hazards with
certain metals
Limitations on part geometry because metal
powders do not readily flow laterally in the
die during pressing
Variations in density throughout part may be a
problem, especially for complex geometries
Manufacturing Processes
Prof Simin Nasseri Chapter 16 5
Usual PM production sequence
Blending and mixing (Rotating drums, blade
and screw mixers)
Pressing - powders are compressed into
desired shape to produce green compact
Accomplished in press using punch-and-die
tooling designed for the part
Sintering green compacts are heated to
bond the particles into a hard, rigid mass
Performed at temperatures below the
melting point of the metal
Manufacturing Processes
Prof Simin Nasseri Chapter 16 6
PM Work Materials
Largest tonnage of metals are alloys of iron,
steel, and aluminum
Other PM metals include copper, nickel, and
refractory metals such as molybdenum and
tungsten
Metallic carbides such as tungsten carbide are
often included within the scope of powder
metallurgy
Manufacturing Processes
Prof Simin Nasseri Chapter 16 7
PM Parts
A collection of powder metallurgy parts.
Manufacturing Processes
Prof Simin Nasseri Chapter 16 8
Engineering Powders
A powder can be defined as a finely divided
particulate solid
Engineering powders include metals and
ceramics
Geometric features of engineering powders:
Particle size and distribution
Particle shape and internal structure
Surface area
Manufacturing Processes
Prof Simin Nasseri Chapter 16 9
Measuring Particle Size
Most common method uses screens of different mesh
sizes
Mesh count - refers to the number of openings per linear
inch of screen
A mesh count of 200 means there are 200 openings
per linear inch
Higher mesh count = smaller particle size
Figure 16.2 Screen mesh
for sorting particle sizes.
Manufacturing Processes
Prof Simin Nasseri Chapter 16 10
Particle Shapes in PM
Figure 16.3 Several of the possible (ideal) particle shapes in powder
metallurgy.
Manufacturing Processes
Prof Simin Nasseri Chapter 16 11
Interparticle Friction and Powder Flow
Friction between particles
affects ability of a powder
to flow readily and pack
tightly
A common test of interparticle
friction is the angle of
repose, which is the angle
formed by a pile of powders
as they are poured from a
narrow funnel.
Figure 16.4 Interparticle friction as indicated by the angle of
repose of a pile of powders poured from a narrow funnel.
Larger angles indicate greater interparticle friction.
Manufacturing Processes
Prof Simin Nasseri Chapter 16 12
Lets check!
Smaller particle sizes show steeper angles or
larger particle sizes?!
Finer
particl
es
Smaller particle sizes generally
show greater friction and steeper
angles!
Manufacturing Processes
Prof Simin Nasseri Chapter 16 13
Lets check!
Which shape has the lowest interpartical friction?
Little friction
between spherical
particles!
As shape
deviates from Spherical shapes have the lowest interpartical
spherical, friction!
friction
between
particles tends
to increase
Manufacturing Processes
Prof Simin Nasseri Chapter 16 14
Observations
Easier flow of particles correlates with lower
interparticle friction
Lubricants are often added to powders to reduce
interparticle friction and facilitate flow during
pressing
Manufacturing Processes
Prof Simin Nasseri Chapter 16 15
Particle Density Measures
True density - density of the true volume of the
material
The density of the material if the powders
were melted into a solid mass
Bulk density - density of the powders in the
loose state after pouring
Which one is smaller?!
Because of pores between particles, bulk density is less than true density
Manufacturing Processes
Prof Simin Nasseri Chapter 16 16
Packing Factor
Bulk density
Packing factor = Typical values for loose
true density
powders range
between 0.5 and 0.7
How can we increase the bulk density?
If powders of various sizes are present,
smaller powders will fit into spaces between
larger ones, thus higher packing factor
Packing can be increased by vibrating the
powders, causing them to settle more tightly
Pressure applied during compaction greatly
increases packing of powders through
rearrangement and deformation of particles
Manufacturing Processes
Prof Simin Nasseri Chapter 16 17
Porosity
Ratio of volume of the pores (empty spaces) in
the powder to the bulk volume
In principle
Porosity + Packing factor = 1.0
The issue is complicated by possible existence of closed
pores in some of the particles
If internal pore volumes are included in above porosity, then
equation is exact
Manufacturing Processes
Prof Simin Nasseri Chapter 16 18
Chemistry and Surface Films
Metallic powders are classified as either
Elemental - consisting of a pure metal (slide 39)
Pre-alloyed - each particle is an alloy
Possible surface films include oxides, silica,
adsorbed organic materials, and moisture
As a general rule, these films must be
removed prior to shape processing
Manufacturing Processes
Prof Simin Nasseri Chapter 16 19
Production of Metallic Powders
Chapter 16 20
Production of Metallic Powders
In general, producers of metallic powders are not the
same companies as those that make PM parts
Any metal can be made into powder form
Three principal methods by which metallic powders are
commercially produced
1. Atomization (by gas, water, also centrifugal one)
2. Chemical
3. Electrolytic
In addition, mechanical methods are occasionally used to
reduce powder sizes
Manufacturing Processes
Prof Simin Nasseri Chapter 16 21
Gas Atomization Method
High velocity gas stream flows through expansion nozzle,
siphoning molten metal from below and spraying it into
container
Figure 16.5 (a) gas
atomization method
Check other figures
as well (page 344)
Manufacturing Processes
Prof Simin Nasseri Chapter 16 22
Iron Powders for PM
Figure 16.6 Iron powders produced by decomposition of iron
pentacarbonyl (photo courtesy of GAF Chemical Corp); particle
sizes range from about 0.25 - 3.0 microns (10 to 125 -in).
Manufacturing Processes
Prof Simin Nasseri Chapter 16 23
Conventional Press and Sinter
After metallic powders have been produced, the
conventional PM sequence consists of:
1. Blending and mixing of powders
2. Compaction - pressing into desired shape
3. Sintering - heating to temperature below
melting point to cause solid-state bonding of
particles and strengthening of part
In addition, secondary operations are sometimes
performed to improve dimensional accuracy,
increase density, and for other reasons
Manufacturing Processes
Prof Simin Nasseri Chapter 16 24
Figure 16.7 Conventional
powder metallurgy
production sequence:
(1) blending, (2)
compacting, and (3)
sintering; (a) shows the
condition of the particles
while (b) shows the
operation and/or
workpart during the
sequence.
Manufacturing Processes
Prof Simin Nasseri Chapter 16 25
Blending and Mixing of Powders
For successful results in compaction and
sintering, the starting powders must be
homogenized (powders should be blended and mixed)
Blending - powders of same chemistry but possibly
different particle sizes are intermingled
Different particle sizes are often blended to reduce
porosity
Mixing - powders of different chemistries are combined
Manufacturing Processes
Prof Simin Nasseri Chapter 16 26
Compaction
Application of high pressure to the powders to
form them into the required shape
Conventional compaction method is pressing, in
which opposing punches squeeze the powders
contained in a die
The workpart after pressing is called a green
compact, the word green meaning not yet fully
processed
The green strength of the part when pressed is
adequate for handling but far less than after
sintering
Manufacturing Processes
Prof Simin Nasseri Chapter 16 27
Conventional Pressing in PM
Fill Press Eject
Figure 16.9 Pressing in
PM: (1) filling die cavity
with powder by automatic
feeder; (2) initial and (3)
final positions of upper and
lower punches during
pressing, (4) part ejection.
Watch the single- and double-punch operations
Manufacturing Processes
Prof Simin Nasseri Chapter 16 28
Sintering
Heat treatment to bond the metallic particles,
thereby increasing strength and hardness
Usually carried out at between 70% and 90%
of the metal's melting point (absolute scale)
Generally agreed among researchers that
the primary driving force for sintering is
reduction of surface energy
Part shrinkage occurs during sintering due
to pore size reduction
Manufacturing Processes
Prof Simin Nasseri Chapter 16 29
Sintering Sequence
Figure 16.12 Sintering on a microscopic scale: (1) particle bonding is
initiated at contact points; (2) contact points grow into "necks"; (3) the
pores between particles are reduced in size; and (4) grain boundaries
develop between particles in place of the necked regions.
Watch the sintering operation
Manufacturing Processes
Prof Simin Nasseri Chapter 16 30
Sintering Cycle and Furnace
Figure 16.13 (a) Typical heat treatment cycle in sintering; and (b)
schematic cross section of a continuous sintering furnace.
Manufacturing Processes
Prof Simin Nasseri Chapter 16 31
Densification and Sizing
Secondary operations are performed to increase
density, improve accuracy, or accomplish
additional shaping of the sintered part
Repressing - pressing sintered part in a closed die
to increase density and improve properties
Sizing - pressing a sintered part to improve
dimensional accuracy
Coining - pressworking operation on a sintered
part to press details into its surface
Machining - creates geometric features that
cannot be achieved by pressing, such as
threads, side holes, and other details
Manufacturing Processes
Prof Simin Nasseri Chapter 16 32
Impregnation and Infiltration
Porosity is a unique and inherent characteristic of
PM technology
It can be exploited to create special products by
filling the available pore space with oils,
polymers, or metals
Two categories:
1. Impregnation
2. Infiltration
Manufacturing Processes
Prof Simin Nasseri Chapter 16 33
Impregnation
The term used when oil or other fluid is
permeated into the pores of a sintered PM
part
Common products are oil-impregnated
bearings, gears, and similar components
Alternative application is when parts are
impregnated with polymer resins that seep
into the pore spaces in liquid form and then
solidify to create a pressure tight part
Manufacturing Processes
Prof Simin Nasseri Chapter 16 34
Infiltration
Operation in which the pores of the PM part
are filled with a molten metal
The melting point of the filler metal must be
TM (filler)<TM (Part) below that of the PM part
Involves heating the filler metal in contact
with the sintered component so capillary
action draws the filler into the pores
Resulting structure is relatively nonporous,
and the infiltrated part has a more uniform
density, as well as improved toughness and
strength
Manufacturing Processes
Prof Simin Nasseri Chapter 16 35
Summary
Manufacturing Processes
Prof Simin Nasseri Chapter 16 36
Alternatives to Pressing and Sintering
Chapter 16 37
Alternatives to Pressing and Sintering
Conventional press and sinter sequence is the most widely
used shaping technology in powder metallurgy
Additional methods for processing PM parts
include:
Isostatic pressing
Powder injection molding
Powder rolling, extrusion and forging
Combined pressing and sintering
Liquid phase sintering
Manufacturing Processes
Prof Simin Nasseri Chapter 16 38
Powder Injection Molding
Metal injection molding
Pellets made of powders and
binder
Heated to molding temperature
and injected into a mold
Can create complex designs
Manufacturing Processes
Prof Simin Nasseri Chapter 16 39
Materials and Products for PM
Raw materials for PM are more expensive
than for other metalworking because of the
additional energy required to reduce the
metal to powder form
Accordingly, PM is competitive only in a
certain range of applications
What are the materials and products that
seem most suited to powder metallurgy?
Manufacturing Processes
Prof Simin Nasseri Chapter 16 40
PM Materials Elemental Powders
A pure metal in particulate form
Applications where high purity is important
Common elemental powders:
Iron
Aluminum
Copper
Elemental powders can be mixed with other
metal powders to produce alloys that are
difficult to formulate by conventional methods
Example: tool steels
Manufacturing Processes
Prof Simin Nasseri Chapter 16 41
PM Materials Pre-Alloyed Powders
Each particle is an alloy comprised of the
desired chemical composition
Common pre-alloyed powders:
Stainless steels
Certain copper alloys
High speed steel
Manufacturing Processes
Prof Simin Nasseri Chapter 16 42
PM Products
Gears, bearings, sprockets, fasteners, electrical
contacts, cutting tools, and various machinery
parts
Advantage of PM: parts can be made to near net
shape or net shape
When produced in large quantities, gears and
bearings are ideal for PM because:
The geometry is defined in two
dimensions (cross section is uniform)
There is a need for porosity in the part to
serve as a reservoir for lubricant
Manufacturing Processes
Prof Simin Nasseri Chapter 16 43
