MANUFACT
URING
PROCESSES
LECTURE: PHD. BÀNH QUỐC
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Which part in a
motorcycle can made
by the powder
metallurgy?
GEAR BOX
SPUR GEARS
POWDE
R
METALL
URGY
CONTENTS
01. 02.
CHARACTERIZA 03.
INTRODUCTIO PRODUCTION
TION OF
N TO POWDER OF METALLIC
ENGINEERING
METALLURGY POWDERS
POWDERS
04. 05.
ALTERNATIVE 06.
CONVENTIONAL
PRESSING AND
PRESSING AND EQUIPMENT
SINTERING
SINTERING
TECHNIQUES
01.
INTRODUCTIO
N TO POWDER
METALLURGY
Metal processing technology in which parts are
produced from metallic powders
• Near-net or Net –
ECONOMICS
o shape
POWDER
f manufacturing
process
METALLUR • Involves very little
waste of material
GY
Energy advantages of
Powder Metallurgy
production of a HIGH
volume oil pump gear
Source: [
Economic Considerations for
Powder Metallurgy Structur
al Parts (pm-review.com)
]
material
• Parts having a
ECONOMICS specified level of
o
POWDER
f porosity can be made
• Certain metals that
METALLUR are difficult to
fabricate by other
GY methods can be
shaped by powder
metallurgy
• Certain metals can
ECONOMICS only be shaped with
o PM
POWDER
f • Compares favorably
with most casting
METALLUR processes in terms of
GY dimensional control
• Can be automated for
economical
DISADVANT E
o
AGES • Tooling and equipment
POWDER
f costs are high
• Metallic powders are
METALLUR expensive
GY
• Difficulties with
storing and
handling metal
DISADVANT
o
AGES
powders
POWDER
f
METALLUR
GY
DISADVANT
o
AGES
• Limitations on part
POWDER
f geometry
• Variations in material
METALLUR density throughout
the part
GY
Price of some
metal
powders
Source: https://www.made-
in-china.com/
OUTLINE OF PROCESSES AND
OPERATIONS INVOLVED
OUTLINE OF PROCESSES AND
OPERATIONS INVOLVED
OUTLINE OF PROCESSES AND
OPERATIONS INVOLVED
OUTLINE OF PROCESSES AND
OPERATIONS INVOLVED
PRODUCTS
Of Powder metallurgy
02.
CHARACTERIZA
TION OF
ENGINEERING
POWDERS
A powder can be defined as a finely divided particulate
solid.
GEOMETRI Particle Size and
Distribution
C Particle Shape and Internal
FEATURES Structure
Surface Area
CHARACTERIZATION
OF ENGINEERING
Interparticle Friction and
POWDERS Flow Characteristics
OTHER Packing, Density, and
Porosity
FEATURES Chemistry and Surface
Films
Particle Size and
Distribution
Typical
methods
of particle
size and
size
distributio
n
measurem
ent
GEOMETRIC
Particle Size and
Distribution
Sieve analysis (MC < 400)
Screens
(sieving
)
number of
openings per
Mesh linear inch of
screen
GEOMETRIC
Particle Shape and Internal
Structure 2-4
1
Several of
the
possible
(ideal)
particle
shapes in
powder
metallurgy
.
Aspect ratio - the ratio of maximum dimension to
minimum dimension for a given particle
GEOMETRIC
Surface Area
Shape
factor
Diameter of a sphere of
equivalent volume as the
nonspherical particle
Ks = 6.0 for a sphere. For particle shapes other than spherical,
Ks > 6
GEOMETRIC
Interparticle Friction and
Flow Characteristics
Friction between
particles affects the ability
of a powder to flow readily
and pack tightly.
Flow characteristics are
important in die filling and
pressing
OTHER
Packing, Density, and
Porosity
bulk density
The packing factor is the
divided by the true density
OTHER
Packing, Density, and
Porosity
Porosity ratio of the volume of the pores (empty spaces) in
the powder
OTHER
Chemistry and
Surface Films
Metal powders
Elemental Pre-alloye
OTHER
Copper and
Iron Aluminum Nickel
its alloys
Tungsten, molybdenum,
Stainless High-speed
titanium, tin, and precious
steel steel
metals.
Chemistry and
Surface Films
The large area per unit weight of metal
when dealing with powders.
Oxides, silica, adsorbed organic
materials, and moisture
Must be removed before shape
processing
OTHER
REFERENCES
1. Kalpakjian, S & R. Schmid, S (2010). Manufacturing
Engineering and Technology Seventh Edition.
2. P.GRoover, M. (2010). Fundamentals of Modern
Manufacturing
3. P. W. Lee, Y. Trudel, R. Iacocca and R. Randall, Powder
Metal Technologies and Applications (ASM
Handbook),1998, .
03.
PRODUCTION
OF METALLIC
POWDERS
* In general, producers of metallic powders are not the same companies as
those that make PM parts.
Virtually any metal can be made into powder form. There are three principal
methods by which metallic powders are commercially produced, each of which
involves energy input to increase the surface area of the metal. The methods
are (1) atomization, (2) chemical, and (3) electrolytic. In addition, mechanical
methods are occasionally used to reduce powder sizes; however, these
methods are much more commonly associated with ceramic powder production
and we treat them in the next chapter.
ATOMIZATION
There are multiple ways of creating the molten metal spray.
01. 02. 03.
Molten metal flows by
The gas flows through an gravity through a nozzle
expansion nozzle, siphoning and is immediately Is similar to second,
molten metal from the melt atomized by air jets. The except that a high-
below and spraying it into a resulting metal powders, velocity water stream
container. The droplets solidify which tend to be is used instead of air.
into powder form. spherical, are collected
ATOMIZATION
04.
The gas flows through an
expansion nozzle, siphoning
molten metal from the melt
below and spraying it into a
container. The droplets solidify
into powder form.
OTHER
PRODUCTION
METHODS
Other metal powder production methods
include various chemical reduction processes,
precipitation methods, and electrolysis.
1. Chemical
A common process involves liberation of
reduction
metals from their oxides by use of reducing
agents such as hydrogen or carbon
monoxide. The reducing agent is made to
combine with the oxygen in the compound to
free the metallic element. This approach is
used to produce powders of iron, tungsten,
and copper.
Another chemical process for iron powders
involves the decomposition of iron pentacar-
bonyl (Fe(Co)5) to produce spherical particles Iron powders produced by decomposition
of high purity. Powders produced by this of iron
method are illustrated. pentacarbonyl; particle sizes range from
about 0.25 to 3.0 mm (10–125m-in).
Powders of copper, nickel, and cobalt can be (Photo courtesy of
produced by this approach. GAF Chemicals Corporation, Advanced
Materials Division.)
2&3. Precipitation and
electrolysis
Other chemical processes include precipitation of metallic elements
from salts dissolved in water.
In electrolysis, an electrolytic cell is set up in which the source of the
desired metal is the anode. The anode is slowly dissolved under an
applied voltage, transported through the electrolyte, and deposited on
the cathode. The deposit is removed, washed, and dried to yield a
metallic powder of very high purity. The technique is used for
producing powders of beryllium, copper, iron, silver, tantalum, and
titanium.
03.
CONVENTIONA
L PRESSING
AND
SINTERING
After the metallic powders have been
produced, the conventional PM
sequence consists of three steps: (1)
blending and mixing of the powders;
(2) compaction, in which the powders
are pressed into the desired part
shape;
and (3) sintering, which involves
heating to a temperature below the
melting point to cause solid-state
bonding of the particles and
strengthening of the part.
The conventional powder
metallurgy production sequence: (1)
blending,
(2) compacting,
(3) sintering;
(a) shows the condition of the
particles, whereas
(b) shows the operation and/ or
workpart during the sequence.
01.
BLENDING AND
MIXING OF THE
POWDERS
Blending refers to when
powders of the same chemical
composition but possibly
different particle sizes
areintermingled. Different
particle sizes are often blended
to reduce porosity. Mixing
refers to powders of different
chemistries being combined. An
advantage of PM technology is
the opportunity to mix various
metals into alloys that would be
difficult or impossible to produce
by other means.
*Rotation in a
otation in a drum double-cone *Agitation in a
container screw mixer
Best results seem to
occur when the *Stirring in a
container is between These additives include:
blade mixer lubricants, such as stearates of
20% and 40% full.
zinc and aluminum, in small
amounts to reduce friction
between particles and at the die
wall during compaction; binders,
which are required in some cases
to achieve adequate strength in
the pressed but unsintered parts;
and deflocculants, which inhibit
agglomeration of powders for
Pressing, the conventional
method of compacting
metal powders in PM: (1)
filling the die cavity with
powder, done by
automatic feed in
production, (2) initial, and
(3) final positions of upper
and lower punches during
compaction, and (4)
ejection of part.
2. COMPACTION
(a) Effect of applied pressure during compaction: (1) initial loose
powders after filling, (2) repacking, and (3) deformation of particles;
and (b) density of the powders as a function of pressure. The
sequence here corresponds to steps 1, 2, and 3 in before.
3. After pressing, the green compact lacks
strength and hardness; it is easily crumbled
SINTERI under low stresses. Sintering is a heat
treatment operation performed on the
NG compact to bond its metallic particles, thereby
increasing strength and hardness. The
treatment is usually carried out at
temperatures between 0.7 and 0.9 of the
metal’s melting point (absolute scale).
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.
4. SECONDARY OPERATIONS
PM secondary operations include densification, sizing, impregnation,
infiltration, heat treatment, and finishing.
FIGURE 16.13
(a) Typical heat treatment cycle in
sintering; and (b) schematic cross
section of a continuous sintering
furnace.
*Densification and
Sizing
Repressing is a pressing operation in which the part
is squeezed in a closed die to increase density and
improve physical properties.
Sizing is the pressing of a sintered part to improve
dimensional accuracy.
Coining is a pressworking operation on a sintered part
to press details into its surface.
*Impregnation and
Impregnation is the term used when oil or other fluid is permeated into
Infiltration
the pores of a sintered PM part. The most common products of this
process are oil-impregnated bearings, gears, and similarmachinery
components. Self-lubricating bearings, usuallymade of bronze or ironwith
10% to 30%oil by volume, arewidely usedin the automotiveindustry.
05.
ALTERNATIVE
PRESSING AND
SINTERING
TECHNIQUES
*Impregnation and
Infiltration
Infiltration is an operation in which the pores of the PM part are filled with a molten metal.
The melting point of the filler metal must be below that of the PM part. The resulting
structure is relatively nonporous, and the infiltrated part has a more uniform density, as well
as improved toughness and strength. An application of the process is copper infiltration of
iron PM parts.
5. HEAT TREATMENT AND
FINISHING
Powder metal components can be heat treated and finished by most of the same
processes used on parts produced by casting and other metalworking processes. Special
care must be exercised in heat treatment because of porosity; for example, salt baths are
not used for heating PM parts. Plating and coating operations are applied to sintered parts
for appearance purposes and corrosion resistance. Again, precautions must be taken to
avoid entrapment of chemical solutions in the pores; impregnation and infiltration are
frequently used for this purpose. Common platings for PM parts include copper, nickel,
chromium, zinc, and cadmium.
Selective Laser
-
Sintering (SLS)
Selective Laser Sintering is a an additive manufacturing process that makes use of lasers to
sinter powder materials. These lasers are aimed at defined points, binding the material together
in order to form one, solid part or component.
- The SLS process involves the solidification of a polymer binder material around the steel powder,
one slice at a time.
- In SLS, the powder material is fully melted rather than sintered, unlike that seen in Direct Metal
Laser Sintering . A rather new technology, SLS is used in rapid prototype casting and for the
production of components in small volumes.
Selective Laser Sintering (SLS)
The Process
In SLS, a laser beam traces and selectively sinters powdered metal composite materials into
successive cross-sections of a three dimensional part. Additional powder is deposited onto
each solidified layer and then sintered.
Parts manufactured using this process are built on a platform that adjust in height equal to
the thickness of the layer being created. The powder, being maintained at an elevated
temperature, only fuses when exposed to the laser.
After each layer has been built, the part is placed in a furnace at a temperature of 900°C or
higher - this allows for the polymer binder to burn off. The part is also infiltrated with bronze,
allowing manufacturers to improve the density of the part.
Capabilities
Liquid Phase Sintering
Used for materials that are difficult to sinter, liquid
phase sintering involves the addition of additives to
the powder material. These additives will melt before
the matric phase in the process.
This sintering process has the following stages:
• Rearrangement:
• Solution Precipitation:
• Final Densification:
The solid skeletal network is densified.
05
DESIGN
CONSIDERATIONS
IN POWDER
METALLURGY
• Use of PM techniques is generally suited to a certain class of production
situations and part designs.
• The Metal Powder Industries Federation (MPIF) defines four classes of
powder metallurgy part designs. The four part classes are illustrated in Figure
(1).
● Economics of PM processing. Minimum quantities of 10,000
units are suggested.
● Capability to fabricate parts with a controlled level of porosity.
Porosities up to 50% are possible.
● PM can be used to make parts out of unusual metals and alloys
The geometry of the part must permit ejection
from the die after pressing.
● Although steps in the part are permissible as suggested by the MPIF
classification system (Figure 1).
● Design features such as undercuts and holes on
the part sides, as shown in Figure 2
Figure (2) Part features to be avoided in
PM: (a) side holes and (b) side undercuts.
Part ejection is impossible.
• Vertical undercuts and holes, as in Figure 3.
Figure (3): Permissible part features in PM:
(a) vertical hole, blind and through,
(b) (b) vertical stepped hole,
(c) (c) undercut in vertical direction. These features allow
part ejection.
• Screw threads cannot be fabricated by PM pressing;
• Chamfers and corner radii are possible by PM
pressing, as shown in Figure 4.
• Wall thickness should be a minimum of 1.5mm(0.060 in)
between holes or a hole and the outside part wall.
06.
POWDER
METALLURGY
EQUIPMENT
MPH
1000
SACMI Imola S.C. - MPH 1000
The SACMI Imola S.C. - MPH 1000 powder compaction machine has the ability to
compress metal powder with precision and uniform thickness, resulting in high
durability and consistency of the final product. The machine is designed with an
automatic lubrication system and a high-precision control system, ensuring the
stability and reliability of the powder compaction process.
Advantages of SACMI Imola S.C. - MPH 1000 powder compaction machine:
• High precision
• High uniformity
• High durability
• Automatic lubrication system
• Advanced design
The disadvantages of the SACMI Imola S.C. - MPH 1000 powder compaction
machine include:
• High cost
• Difficult to use
• Requires a highly skilled technical team
TPA500/
•
4HP
The CNC hydraulic multi-plate powder
compaction machine is designed for high
productivity and reproducibility while
maintaining tight tolerances on the
compacted parts.
• It features a modular design and an
interchangeable control system to quickly
set up and change products for optimal
efficiency.
Technical
•
• information
Version with four columns
Adjustable positive stops in pressing position
• Die set change to the rear of the machine
• Closed-loop controlled filler axis
• Installation in a pit
• Closed-loop controlled core rod
• 6-axis robot
• Pressing force: 10.000 kN
• Upper punch stroke: 350 mm
• Filling height: 250 mm
• Core rod travel: 129 mm
• Positioning accuracy: ±0,01mm
Advantages and
disadvantages of TPA 1000
Advantages and disadvantages of TPA 1000 machine:
machine:
• Advantages:
High accuracy in powder pressing
Ability to work with various types of metals and powders
Automatic lubrication system for stable and reliable operation
User-friendly interface for easy operation and monitoring
High productivity and repeatability
• Disadvantages:
Relatively high cost compared to other powder pressing machines
Large and bulky size, which requires a spacious working area
Requires skilled operators with experience in using hydraulic
machines
Limited flexibility in adjusting pressure and other settings during
the pressing process.
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