Powder Metallurgy

 Essentially, Powder Metallurgy (PM) is an art & science of

producing metal or metallic powders, and using them to make
finished or semi-finished products.
 Particulate technology is probably the oldest forming technique
known to man.

 There are archeological evidences to prove that the ancient man

knew something about it.

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 Powder Metallurgy
 An important point that comes out :

 The entire material need not be melted to fuse it.

 The working temperature is well below the melting point of the

major constituent, making it a very suitable method to work
with refractory materials, such as: W, Mo, Ta, Nb, oxides,
carbides, etc.
 It began with Platinum technology about 4 centuries ago… in
those days, Platinum, [MP = 1774°C], was "refractory", and
could not be melted.

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 Powder Metallurgy Process

 Powder production
 Blending or mixing
 Powder compaction
 Sintering
 Finishing Operations

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 Powder Metallurgy Process

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 Powder Metallurgy Processing
Powder fabrication

POWDER Size and shape characterization

Microstructure (e.g.. dendrite size)
Chemical homogeneity, and ppt. size

Compaction
Sintering
PROCESSING
Forging/Hot pressing

Density, Porosity
Ductility, Strength
PROPERTIES Conductivity
Other functional properties

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 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

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 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
 Atomization (by gas, water, also centrifugal one)

 Chemical

 Electrolytic

 In addition, mechanical methods are occasionally used to reduce

powder sizes
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 Particle Shapes in Metal Powders

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 Conventional powder
metallurgy production
sequence:
 blending
 compacting
 Sintering

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 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 .

PM technology allows mixing various metals into alloys that would

be difficult or impossible to produce by other means.
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 Blending or Mixing
 Blending a coarser fraction with a finer fraction ensures that the
interstices between large particles will be filled out.
 Powders of different metals and other materials may be mixed in
order to impart special physical and mechanical properties
through metallic alloying.
 Lubricants may be mixed to improve the powder’s flow
characteristics.
 Binders such as wax or thermoplastic polymers are added to
improve green strength.

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 Blending
To make a homogeneous mass with uniform distribution of
particle size and composition.
 Powders made by different processes have different sizes and
shapes
 Mixing powders of different metals/materials
Combining is generally carried out in
 Air or inert gases to avoid oxidation
 Liquids for better mixing, elimination of dusts and reduced
explosion hazards

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 Bowl Geometries for Blending
Powders

Some common equipment geometries used for

blending powders
(a) Cylindrical, (b) rotating cube, (c) double A mixer suitable for blending metal
cone, (d) twin shell powders.
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 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 work part 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.

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 Compacting
 Press powder into the desired shape and size in dies using a
hydraulic or mechanical press
 Pressed powder is known as “green compact”
 Stages of metal powder compaction:

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 Compacting
Powders do not flow like liquid, they simply compress until an
equal and opposing force is created.
– This opposing force is created from a combination of
(1) resistance by the bottom punch and
(2) friction between the particles and die surface

Compacting consolidates and dandifies the component for

transportation to the sintering furnace.

Compacting consists of automatically feeding a controlled amount

of mixed powder into a precision die, after which it is compacted.

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 Compacting

Compacting is usually performed at room temperature. Pressures

range from 10 tons per square inch (tons/in2) (138 MPa) to 60
tons/in2 (827 MPa), or more.
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 Figure: (Left) Typical press for the compacting of metal powders. A removable die
set (right) allows the machine to be producing parts with one die set while another is
being fitted to produce a second product.
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 Compaction Sequence

Figure: Typical compaction sequence for a single-level part, showing the

functions of the feed shoe, die core rod, and upper and lower punches. Loose
powder is shaded; compacted powder is solid black.

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 Friction problem in cold
compaction

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 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

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 Sintering

 Parts are heated to ~80% of melting temperature.

 Transforms compacted mechanical bonds to much stronger metal
bonds.
 Many parts are done at this stage. Some will require additional
processing.
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 Sintering Sequence
 Parts are heated to 0.7~0.9 Tm.
 Transforms compacted mechanical bonds to much stronger
metallic bonds.

Figure: 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.
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 Sintering
Third stage:
Sintered product is cooled in a controlled atmosphere.
– Prevents oxidation and thermal shock

Gases commonly used for sintering:

H2, N2, inert gases or vacuum

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 Sintering Cycle and Furnace

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 Powder Rolling

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 Powder Metallurgy Merits
 Near Nett Shape is possible, thereby reducing the post-production
costs, therefore:

 Precision parts can be produced

 The production can be fully automated, therefore,

 Mass production is possible

 Production rate is high

 Over-head costs are low

 Break even point is not too large

 Material loss is small

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 PM Parts

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 Powdered Metal Transmission Gear Connecting Rods:
 Warm compaction method with 1650-ton Forged on left; P/M on
press right
 Teeth are molded net shape: No machining
 UTS = 155,000 psi
 30% cost savings over the original forged part

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