(4 11 CHAPTER POWDER METALLURGY AND PLASTICS Pee sai cali 11.9. Plastics 41.10. Properties of Plastics 41.41. Classification of Plastics Properties of Metal Powder 41.42, Processing of Thetmosetting Plastic Processing of Powder 41.13. Processing of Thermoplastic Plastics | Applications of Powder Motallurgy 11-14. Electroplating ‘pavaniages of Povider Metalllurgy 11-18. Galvanizing Disadvantages of Powder Metallluray Introduction Powder Metallurgy Process Powder Manutacture 41.1. INTRODUCTION Powder metallurgy is an art of manufacturing commercial articles from powdered metals and alloys, This process consists of blending and pressing (compacting) of powdered particles into desired shape ‘and then heating in a controlled atmosphere to bind the particles and improve their properties (sintering). © This process is economically feasible for mass production cof small. intricate parts of high precision and also eliminates the need {or additional machining or finishing. © [It can produce controlled degree of porosity. @ itis used where desired properties and characteristic obtain by any other method. © Automobile applications acc: ounts { 2 0 metallurgy market. orinearty 75 are difficult 10 of powder are oilless sett @ Some examples of powder metallurgy products ctrical lubricating bearings, tungsten carbide cutting tools, ele 212yr FONER METALLURGY AND PLASTICS contacts, turbine blades, copper coins, tungsten wire, household appliances, etc. 44.2, POWDER METALLURGY PROCESS Powder metallurgy consists of following stages : 4. Powder Manufacture 2, Mixing or Blending 3. Compacting 4, Sintering DER MANUFACTURE Properties of powder metallurgy product depends upon the properties of metal powder such as particle shape, particle size, size distribution and surface texture of particles. Following processes are commonly used for producing powders. 1. Atomization In this process molten metal is fragmented into droplets by using stream of water and air. These metal droplets solidifies into small particles of various irregular shapes. Procedure : Molten metals filled in hopper like container called tundish, which is fitted on top of container. As metal flows down in form of stream through the nozzle, water strikes from both sides on stream of metal, causing rapid cooling of metal in form of small particles. The size and shape of particles depends upon velocity and medium of atomizing jets, temperature of liquid, and environment provided for cooling. LADLE MOLTEN METAL ATOMIZING CHAMBER uaa PARTICLES, Fig, 11.1, Atomization.: - MANUFACTURING PROCE aap taney ‘Anothor tochnique of atorni? ation is rotating electrode prox 4 of lwo olactrodes, one imado of tungsten and other made whose atomization 16 to be done. qungsten electrode is none nonconsumable whereas pthar electrode is rotating and consumable, 4 struckod botwoon the Figotrodes duo to which intense heat is produced 4 tho motal molts from rotating electrodes. Molten metal is cooled upto de tomporaturo and got sraorted into small particles which are collect the bottom. cons 2. Reduction Process In this process oxides or refined ores are reduced in presence of reducing agont ata temperature below their melting point by chemical process. Thi roducing agent may be carbon monoxide or hydrogen. The spongy material, obtained after reduction is crushed and ground to produce a powder. : 3. Electrolysis This process is similar to electro anode and other metal plate act at through the electrolyte, metal powder / washed with water and dried. Alter drying to produce powder of desired grain size. powder and is used for tin, silver and copper metals. plating in which one metal plate acts as cathode. When high current is passed deposited on cathode. Cathode it is scrapped off and pulverized This process produces the fine 4, Milling or Crushing ers and stampers break down the metal In this process millers, crush is suitable for brittle into small particle by crushing and impact. This process material. 5. Shotting In this process molten metal is passed throw produce large spherical particles. PROPERTIES gh a sieve into water 10 aL 1. Apparent Density resented e powder and repre’ her It ig defined as actual volume filled out by loos} as mass per unil volume of powder. Apparent density depends UPON ical of factors such as size, shape, distribution of particles an ii composition. Portion ‘of component can be made hard a! controlling apparent density. attoo!® 2. Purity fone" Powder must be pure. Impurity prosent in the m sintering and briquetting procoss, reduces life of dies a” mechanical properties. ows ot etal P' y als?4. particle Shape Method of powder manutacture decides the particle shape which may be flat, irregular, angular, lamellar, spherical or dendritic. In these shapes jnegular shaped particles achieve good green strength. The shape of the particle affects compactness, strength and porosity. 4. Size of Particle and Distribution The size of particle is defined by many methods. It has good influence over porosity, density, compressibility and shrinkage. If size of particles is same then porosity of metal increases otherwise decreases. If particles have fine grains, density of metal increases otherwise decreases. 5, Flowability It shows the flowing ability of metal powder. Time taken by a definite quantity of powder to flow out of a standard orifice is known as flow rate. There are two parameters that are governed by flow rate one is production tate and other is time required to fill the mould. Flowability depends upon size, shape and distribution of particles. 6. Compressibility Itis defined as the ratio of initial volume of the powder (unpressed volume) to final volume (pressed volume) after compression, It imparts green strength to powder also known as mechanical strength of compressed part. 7. Sintering Ability It is the ability by which metal powder promotes adhesion between particles. It should be high enough to produce good quality products. Regular shapes have good sintering properties. 11.5. PROCESSING OF POWDER Processing of powder has been classified into two groups. 1. Primary processes 2. Secondary processes -5.1, Primary proc (i) Blending or Mixing (ii) Briquetting or Compacting iii) Presintering (iv) Sintering BeMANUFACTURING PROCESSES METAL POWDER ADDITIVE Ne BLENDING i BRIQUETTING SINTERING SECONDARY PROCESS FINAL PRODUCT Fig. 11.2. Flow Chart of Powder Metallurgy Process. (i) Blending or Mixing Blenaing is done to obtain uniform distribution of particle size. Blending | is required when different metal powders are used or nonmetallic particles I are added to impart some specific properties. Blending is not required for il metal powder having correct particle size distribution. Mixing of constitutes may be wet or dry. In wet mixing, water or solvent is used to reduce explosion hazard and dusting Lubricants such as graphite, stearic acid are added to reduce the die wall friction, friction between the particles and improve the flow characteristic, green strength and compressibility. Binders are also added to develop adequate green strength (i!) Briquetting or Compacting In this process powders are compacted and densified into an accurate size oF shape by application of pressure at room temperature and the resulting compact is known as green compact. Pressure increases the hardness: strength and density Compacting 1s done in hardened steel dies by use of punches. If one punch is used, pressure will not be uniformly distributed throughout the mass, so wo punches are used one trom the top and other from the bottom. Lower punch 1s called ejector because it removes the compressed part. Powder is compressed nearly to one third of Its original volume.POWER METALLURGY AND PLASTICS UPPER PUNCH METAL POWDER LOWER PUNCH Fig. 11.3. Compacting. Compacting pressure may range from 40 to 1650 MPa depending on material and application. Compacting is done with mechanical press, raulic press and rigid tools. Mechanical press is used for low pressure hydraulic press is used for high pressure. i) Presintering tis defined as a process in which green compact is heated to temperature slow sintering temperature to increase the strength, It also removes the “lubricant and binders added during blending. Presintering is not done when machining is not required. (lv) Sintering mpacted parts are heated to high In the sintering operation, co! but below the melting point of material lemperature in controlled atmosphere being sintered. Heated part is held for certain period at correct temperature '0 permit bonding of particles. It increases strength and hardness of the part lo the require extent. Most of metals are sintered up to certain tefiperatue, Which is 70% to 80% of thelr melting point, Some refractory metal are siete Upto 80%. If compacted part is made of more than one material then siteting 'emperature may be more than the melting temperature of one or Component.a Sintering operation involves tiiree stages. (a) Purge or Burn off Chamber : It is designed to rem, substances, lubricants, binders and to raise the temperature of controlled way. (b) High Temperature Stage : To enable solid State diffu bonding between the particles, part is heated to sintering temper. held for sufficient time varying from 10 minutes to several hours. (c) Cooling Period : In this stage temperature of product is gradually lowered in controlled atmosphere to prevent oxidation and thermal shock due to rapid cooling. Allthree states are conducted in protective atmosphere to avoid oxidation, Protective atmosphere can be of hydrogen, dissociated ammonia or cracked hydrocarbons, which can reduce oxides and harmful gases present in particles. Due to formation of metallurgical bonds between powder particles strength, toughness, ductility, electrical and thermal conductivity of compacted part increases, ‘ OVE Volatiie Compacts in, sion ang ‘ature ang 11.5.2. Secondary Process Secondary operation are performed to enhance precision, improve Properties and special characteristics. Various secondary process are (i) Sizing : This operation is performed to correct the dimension of sintered part by improving dimensional tolerance of part. (ii) Coining : Coining is used to close the voids and provide the desired density. (iii) Machining : Machining is done to hold very close tolerances and producing features which are not possible through primary processes. (iv) Infiltration : In infiltration, molten metal is used to {ill the porosity in the sintered compact. It increases the strength, density and hardness which is not possible through sintering alone. (v) Impregnation : In this process pores in sintered part are filled with oil and provides self-lubricating Properties to parts. (vi) Plating : Plating of sintered part is done to prevent corrosion and provide protective almosphere. 1: F_ POWDER METALLLURGY 1. Porous or permeable products such as bearings, filter and flow regulators, 2. Self lubricated bearings. 3. Clutch facing and brake lining, 4. Porous fillers and bearings.HY AND PLASTICS ee g agnets: cement carbide tools and dies, pump rotors and gears. 3. Motor bushes. yt ADVANTAGES OF POWDER METALLLURGY 1 production rate is high. . scrap is reduced, . Complex shapes can be made. |. Controlled porosity is achieved. Good surface finish and accurate dimension is obtained which eliminate further machining in most cases because of very high dimensional accuracy. 6. Labour cost is low. 7. Bimetallic and laminated parts can be produced. aren 141.8. DISADVANTAGES OF POWDER METALLLURGY 1. Not economical for small scale production. 2. Dies and equipments cost is high. 3. Not possible to eliminate the porosity completely in parts. 4. Intricate designs are difficult to attain. 5. Size of partis limited. 11.9. PLASTICS Plastics are synthetic organic material, which can be formed into diferent shapes with the application of heat and pressure. Plastics are characterized by large molecules called polymers which are composed of large number of small molecules called monomers. Synthetic resins are usually referred as plastics and their compounds can be mould ; extruded, cast or used as thin film or coatings They offer low density tow tooling cost, good corrosion resistance, good dielectric Cee design versatility. Generally used natural polymers are resin. . shelter, etc 1. Good thermal and electrical Insulation eapaclt 2. Light weight and low density. 3. Good surface finish is obtained. 4. High resistance to corrosion.20) i 5. High antifriction properties. 6. Good chemical stabiliy. 7. Not affected by gases and moisture. 8. Easy to mould due to low melting point. 9. High damping capacity. | x 10. High strength to weight ratio. ' 11.11. CLASSIFICATION OF PLASTICS Plastics are classified into two main groups : j 11.11.1. Thermosetting Plastics These plastics can be soften only once and can't be resoften again under heat due to non-reversible chemical changes. In other words the useful properties of plastics get destroyed at high temperature making it unsuitable for reuse. These plastics have a highly cross-linked or three dimensional framework structures. ee Example (i) Phenol formaldehyde (ii) Urea (iii) Epoxy resins (iv) Polyesters (v) Alkyds (vi) Epoxides or epoxy resins 11.11.2. Thermoplastic Plastics These plastics can be repeatedly softened by heating and hardened b cooling so can be repeatedly shaped. Thermoplastic materials don’t have definite melting temperature. It softens over a range of temperature. Example (i) Polyethylene (ii) Polystyrene (iil) Vinyl resin (iv) Polyamide (v) Acrylic resinPOWER METALLURGY AND PLASTICS i 41.11-3- Difference between Thermosetting and Thermoplastic Thermosetting Plastic ‘Once set cannot be resoften and remoulded into any new shape by application of heat. 2. Formed by condensation polymerization. 3. Polymers of thermosetting plastic are composed of cross linked molecules. 4. These plastics have better heat resistance, better chemical resistance and less creep. 5. Cannot be mechanically softened or deformed at high temperature. 6. Application of heat leads to degradation and decomposition. 7. These material become hard after heating (heat setting resins). Making a part, rod, sheet or tube is difficult. 9. Plasticity of these material does not increase with increase in temp- rature. 10. Examples : 1" Polyesters, epoxides, Thermoplastic 1. Can be resoften and remoulded into any shape by application of heat. 2. Formed by addition polymerization. 3. Polymers are composed of chain molecules. 4. These plastics have less resistance to heat and chemical effect and have high creep. 5. Gan be mechanically deformed or softened at high temperature. 6. Application of heat soften the plastic and retain chemical composition. 7. These material become hard after cooling (cold setting resins). 8. Various shapes can be produced easily. 9. Plasticity of these material increase with increase in temperature. 40.Examples : Polyethylene polystyrene, phenolics, phenol formaldehyde etc. | vinyl resin. polyamide FF THERMOSETTING PLASTIC There are number of m thermosetting plastics. Comm 11.12.1. Compre Compression moulding form of solid granules ar downwards and applies pres shape, To allow chemical chant and polymerization takes place. Opened and part is remo’ jethods whi only used methods are * is similar to cl 9 placed into sure to compress ges mould is kep When the product ge! ved. It is ec ch are used for processing of sion Moulding losed die forging in which plastic in heated cavity. Punch descends he compound into required t closed for sufficient time ts hardened, mould is onomical for small products| — PuNcH MANUFACTURING PROCESSES aa TS }*—— GUIDE PINS FINAL PRODUCT POWDERED RESIN Fig. 11.4. Compression Moulding. 11.12.2. Transfer Moulding It is the modification of compression moulding in which turbulence and uneven flow of molten plastic has been eliminated. Unpolymerized raw material is placed in plunger cavity where it is heated to molten state. Plunger move downwards and forces the molten metal to flow through sprues and gate into die cavities. Some advantages of this Process are : (i) Little pressure exists until the cavity is completely filled. (ii) Operation is easy (iii) It can be used where inserts are incorporated in the product PLUNGER —> PREFORMPOWER METALLURGY AND PLASTICS (z23) 11.13. PROCESSING OF THERMOPLASTIC PLASTICS NG OF THERMOPLASTIC PLASTICS 11.13.1. Infection Moulding ___——~_ Wt is widely used for high voturne production. Raw material in form of Solid granules is fed by gravity through a hopper in the cavity. As ram advances, the material is forced forward in a heated chamber. After that material ts forced through thin section, called torpedo section where it is heated, meted and superheated in range of 200°C to 300°C. The material being under compression softens and is forced into the mould cavity through the nozzle where material solidifies on cooling and product is formed, It is {ast process and is suitable for making parts with complex threads and inticrate shapes. I! is commonly used for thermoplastic plastics WEATING JACKET HOPPER Z ATMs ae Z Ky FINISHED. PRODUCT 5 Fig. 11.6. Injection Moulding. 11.13.2. Extrusion Moulding = __ ~~ This process is suitable for thermoplastic material. Material can be extruded into various shapes like shoots, ropes Pipes, otc. Thermoplastic Powder is fed into chamber through the hopper tn this chamber rotating Screw advances the material through a Prehoating section where material {8 uniformly heated, and compressed. Alter that maternal is forced through heated orifice of the die Shape of product depends upon the size ot orifice. Product is cooled by jets of ait and sprays of water to harden it sutticiently nd is carried away by conveyor It is inexpensive and continuous method 8nd is used to form tubes, pipes and even coated wire HEATING CYLINDER HEATING jue 10 CONVEYOR ExtHUDED PRODUCT Tig. 11,7, Extrusion Moulding.