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POWDER METALLURGY

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10 views4 pages

POWDER METALLURGY

Uploaded by

rashidulislamra4090
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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POWDER METALLURGY

Introduction
Powder metallurgy is the art and science of producing fine metal
powders and then making objects from individual, mixed or alloyed
metal powders with or without the inclusion of non-metallic
constituents. (Or) Powder metallurgy is a branch of metallurgy which
deals with the production of metal and non-metal powders and
subsequently manufacture of components by using these powders.
Powder Metallurgy Process

1. Producing metal powders


2. Mixing
3. Pressing
4. Sintering
5. Finishing and sizing the final product.

Figure: Flow chart of powder metallurgy process


1. Producing metal powders
Various methods for manufacturing powders are

i. Atomization
ii. Reduction
iii. Crushing
iv. Milling
v. Shotting
vi. Electrolysis
Atomization

The process of metal spraying against a stream of compressed air or inert gas is
atomization. It is an excellent means of producing metal powders from many
of the low temperature metals such as lead, aluminium, zinc and tin.
Reduction
Reduction process is carried out in an atmosphere controlled furnace.In reduction
process, the compounds of metals usually oxides like iron oxides are reduced with
CO/H at temperature below melting point of metal. Tungsten, molybdenum, iron,
cobalt, nickel powders are commercially produced by this process.

Crushing

Process of passing the metal powders against two rollers so that the metal
powders are crushed to required size. Crushing requires equipments such
as stamp, hammers, and jaw crushers.
Milling
Milling is carried out by using equipments such as ball mill, rod mill, impact mill,
disk mill etc. In ball milling, material to be powdered is collected in a container
with a large number of hard steel balls. These balls hit the material and break it
in powder form.
Shotting

The process of pouring molten metal through a sieve or orifice and cooling by
dropping into water is known as shotting. This process gives spherical or pear-
shaped powder particles.

Electrolysis
In this method, an electrolytic cell is set up as shown in figure. The desired metal
is made to act as anode. Anode slowly dissolves and gets deposited on the
cathode from where the deposit is removed, washed and dried.
2. Mixing / blending of metal powders

Blending: Mixing powder of the same chemical composition but different sizes

Mixing: Combining powders of different chemistries

3. Compacting / Pressing of metal powders.


Pressing the powders into desired part shape as closely as possible to final
dimensions

Powders are compacted using high pressure.

4. Sintering
• Sintering is the heat treatment process, to bond the metallic particles,
thereby increasing strength and hardness

• Sintering consists of heating pressed metal compacts in batch or


continuous furnaces to a temperature below the melting point of
material.
• Most metals are sintered at 70 % to 80 % of melting temperature.

5. Finishing Operations
A number of secondary and finishing operations can be applied after sintering,
some of them are:
• Sizing : cold pressing the sintered part to improve dimensional
accuracy.

• Coining : cold pressing to press details into its surface.

• Impregnation : oil fills the pores of the part


• Infiltration : pores are filled with a molten metal

• Heat treating : annealing can be done for stress relief in powder


metallurgy part.

• Machining : creates geometric features that cannot be achieved by


pressing, such as threads, side holes, and other details
Advantages of powder metallurgy process
• A combination of metals and non-metals powdered parts can be
manufactured.
• High dimensional accuracy is achieved.
• Fine surface finish is achieved.
• No material is wasted as scrap. This process makes use of 100 %
raw material unlike casting, press forming etc.
• Porous parts can be produced which is not possible by any other method.
• Highly qualified or skilled person is not required for handling powder
metallurgy method.
• Large scale production of small parts with this process gives efficient
results.
• Production of cemented carbide tools is possible only by this process.
• It eliminates numerous machining operations.
• Powder metallurgy parts can be easily brazed, welded, soldered.
• Process is economical as mass production process.
Limitations of powder metallurgy process

There are limitations and disadvantages associated with P/M processing. These
include:
• High tooling costs.
• Expensive raw materials (powders).
• Relatively long parts are difficult to manufacture.
• Difficult storing and handling of powders
• Powder metallurgy is not economical for small scale production.
• Articles produced by powder metallurgy process possess poor ductility.
• Difficult to produce high purity powder.
• Due to porosity, specified mechanical properties are difficult to be obtained.
• P/M parts show poor plastic properties.
• Punches, dies, rolls etc are very costly and also very bulky to transfer from
one place to another

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