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Lecture 02
Credits 3 (3-0-0)
Instructor: Dr. Sagar Sarkar
Friday (11:00 AM-12:00 PM) – Slot F
Production of Metallic Powders
Near Net Shape Manufacturing (MCL133)
1
Recap
• What is need for study the powder metallurgy?
• Relevance to the modern manufacturing processes
• Application wise
• Specific materials (say magnetic materials)
• A brief history of powder metallurgy
• Overview of the topics to be covered
2
How to produce metal powders
• Solid-State Reduction
• Atomization (gas/water)
• Electrolysis
• Chemical
Which method to use?
3
Solid-State Reduction
(a) Roll crusher (b) Ball mill
Double roll crusher Single roll crusher
https://www.youtube.com/watch?v=MaKjOySPd1g
https://www.youtube.com/watch?v=r0XZTIWXQ3M
4
Solid-State Reduction
Ball & Rod Mill operations https://www.youtube.com/watch?v=bljhXsH8-ME
Vibratory Disc Mill operations https://www.youtube.com/watch?v=aD_9Ti3RxQ0
Tiltable Ball & Rod Mill operations https://www.youtube.com/watch?v=Uds_533gS7Q
Laboratory Digital Ball Mill
5
Atomization (gas/water)
Produce a liquid-metal stream by injecting molten metal through
a small orifice
Stream is broken by jets of inert gas, air, or water
The size of the particle formed depends on:
• Temperature of the metal
• Metal flowrate through the orifice
• Pressure of jet
• Nozzle size and jet characteristics
6
Atomization (gas/water)
The process consists of main three stages
• Melting
• Atomization
• Solidification and cooling
Melting is done by induction, arc, plasma or electron-beam
technique to maintain purity of melt.
Atomization is done by high velocity water, compressed air or inert
gas.
The disintegrated particles are solidified in controlled atmosphere,
vacuum , air or water.
Main two types of techniques: Water Atomization, Gas Atomization
7
Gas atomization
https://www.youtube.com/watch?v=ndZoucUHrtc
https://www.youtube.com/watch?v=vouCR6bhCt0
8
Water/liquid atomization
https://www.youtube.com/watch?v=bQnQvCk9x6E
9
Electrolysis
• Electrolyte composition and concentration, temperature, and current
density
• Further processing such as washing, drying, reducing, annealing, and
crushing is often required,
• Yields high-purity and high-density powders.
• Copper , iron, chromium, and magnesium powders are also produced this
way.
• Due to its associated high energy costs, electrolysis is generally limited to
high-value powders such as high-conductivity copper powders.
https://www.youtube.com/watch?v=3X9c6epL7HQ
10
Chemical
• Oxide reduction, Precipitation from solutions, and Thermal
decomposition.
• The powders produced can have a great variation in properties and yet
have closely controlled particle size and shape.
• Oxide-reduced powders are often characterized as "spongy," due to pores
present within individual particles.
https://www.youtube.com/watch?v=iP1Im4QILS0
11
Chemical
• Solution-precipitated powders can provide narrow particle size distributions
and high purity.
https://en.wikipedia.org/wiki/Precipitation_(chemistry)
• Thermal decomposition is most often used to process carbonyls. These
powders, once milled and annealed, exceed 99.5% purity.
https://www.youtube.com/watch?v=BQymwRKKTTM
12
Have a look
Conventional Press-and-Sinter Powder Metallurgy
https://www.youtube.com/watch?v=I39m28NZ7_s
https://www.coursera.org/lecture/aerospace-materials/5-1b-methods-for-
producing-powder-materials-part-2-NN1lP
13
Thank you
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