MT Powder Metallurgy

ME-402
MODULE-3
POWDER METALLURGY PROCESS

Ramesh K Nayak, SME, KIIT University
BY
RAMESH KUMAR NAYAK

ASST. PROFESSOR, SME
ME-402 Manufacturing Technology-I CR-3 1. Foundry Process: Pattern making, pattern materials, allowances, types of pattern, sand casting types, sand cast,moulding procedure, types of sand, gates and riser (basic design considerations) essential properties of moulding sand, core making, types of cores. Essential qualities, core mixtures and binder sand testing, Mould and core hardness test, fineness test, clay content test, permeability test, moisture content test, sand conditioning. Basic idea about cupolas and other melting furnaces. Melting and pouring procedures for cast Iron, Steel and nonferrous castings. Cleaning of casting and defects in casting, die casting. Precision investment casting, shell moulds, centrifugal casting processes, permanent moulds casting, dies casting. 2. Metal Working Process: Hot and cold working of Metals: Basic Principles of hot and cold working of metals. Rolling: Types of Rolling, Rolling equipments hot and cold rolling, General deformation pattern, Pressure and forces in rolling. Forgings: Smith forging, Drop forging, press forging & Machine forging, Description of Presses and hammers, forging defects. Forging die design. Extrusion: Direct, Indirect and impact extrusion and their applications, Extrusion defects. Drawing: Wire and rod drawing, Tube drawing, Process variables in drawing process.
3. Powder Metallurgy Process: Preparation of powder, properties of powder, fabrication methods & procedure,applications, advantages.
4. Fabrication Processes: Classification, types of welding joints, Gas welding principles, types of flames, equipment, techniques of gas cutting. Electric Arc Welding: Principles of electric welding equipments and electrodes (in brief), principles of Inert Gas Welding. TIG, MIG, sub-merged arc welding. Atomic hydrogen welding, plasma are welding. Resistance Welding: Principle of forge welding, spot-seam, Projection, Upsetbutt welding, flash welding. Thermit welding, electro-slag welding, friction welding Brazing, Soldering. Text Book: 1. Manufacturing technology: P.N.Rao (Tata Mc-Graw Hill, Publication. Co.Ltd.) Reference Books: 1. Principle of Metal Casting: Hein and Rosenthal. 2. Manufacturing Science: A. Ghosh & A.K.Mallick (EWP) 3. Principle of Manufacturing Materials and Processes: J.S. Cambell (TMH) 4. Welding & Welding Technology - R.Little (TMH)
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Definition of Powder Metallurgy (P/M)

Art and science of producing fine metal powders and semifinished or finished components or parts from individual, mixed or alloyed metal powders with or without the inclusions of non-metallic constituents
WHY POWDER METALLURGY ?

Feasible when
1. The melting point of a metal is too high such as W, Ta, Mo 2. The reaction occurs when melting such as Zr and for super hard tool materials 3. Limitation of solubility of solute in melting/ liquid condition 4. Near-net shape, No waste, controlled porosity, Dimension control better than casting
BASIC STEPS IN POWDER METALLURGY (P/M)

1. Powder Manufacture 2. Powder Characterization & Testing 3. Powder Conditioning and Blending/Mixing 4. Powder Compaction
5. Sintering
6. Heat Treatment & Finishing Operations
INDUSTRIAL PROCESSING STEPS
POWDER PRODUCTION
Atomization
the most
common Others

Chemical reduction of oxides Electrolytic deposition
Different
shapes produced
Will affect compaction process significantly
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Comminution
(a)
Fig: Methods of mechanical comminution, to obtain fine particles: (a) roll crushing, (b) ball mill, & (c) hammer milling This method is generally applied for the preparation of powders of brittle materials
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Physico-Chemical Processes
Condensation
Used for production of zinc and magnesium powders
Modified distillation technique

Zinc oxide mixed with charcoal is heated until zinc vapor is formed by the reaction of zinc oxide and carbon monoxide. Subsequently, zinc vapor is condensed in the first and second condenser units in form of fine zinc powder Main disadvantage is high oxidation, which is difficult to control
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Thermal Decomposition Gaseous

Pyrolysis Method
Used for production of iron and nickel powders from their carbonyls, which at a certain temperature and pressure decompose to give a gas and a metal Carbonyls like Fe(CO)5 and Ni(CO)4 are obtained by passing carbon
monoxide over spongy or powdered metal at suitable temperature

(200 270 0C) and pressure (70 200 atm). At reduced pressure (one atm) and elevated temperature (150 400 0C), both these carbonyls decompose to form carbon monoxide gas and metal powder
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Reduction
Most widely used, oldest, convenient, economical and extremely flexible method (regarding controlling shape, size and porosity) of
producing iron, copper, nickel, tungsten, molybdenum and cobalt powders Extremely fine powders with irregular shaped particles are generally formed Metal compounds generally oxides (small quantities of formats, oxalates and halides) are reduced by the use of reducing agents (hydrogen, dissociated NH3, CO, coal gas, enriched blast furnace gas, natural gas, partially combusted hydrocarbons or alkali metal vapors and carbon) either in solid or gaseous form
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Electro Deposition from Aqueous Solutions &

Fused Salts (Electrolysis Method)
Reversed adaptation of electroplating technique, used for commercial production of copper, beryllium, iron, zinc, tin, nickel, cadmium, antimony, silver and lead powders Main advantages are economical production, high purity, uniform shape, size and size distribution Main disadvantages are unsuitability for alloy powders, time consuming method, low productivity and high cost
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Precipitation from Aqueous Solution

Addition of less noble metal higher in the electromotive series displaces and precipitates the metal from its aqueous solution Produces very fine powders with low apparent density Used extensively for production of gold and silver powders
Precipitation from Fused Salt
Similar to precipitation from aqueous solution and only difference

is that salts of metal fused with some reactive agents are heated to high temperature to produce metal powders powders Used for the production of zirconium, beryllium and thorium
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Hydrometallurgical / Gaseous Reduction

Metal powders of nickel, cobalt and copper are produced on commercial scale Involves reduction of aqueous solutions or slurries of salts of metals with hydrogen under particular combination of high
pressure (400 900 psi) and temperature (130 210 0C)
Characterized by use of low grade of ores and production of very highly pure powders with narrow range of particle size distribution having spherical shapes and high apparent density
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Oxidation and decarburization

Used for the production of pure reactive metal powders,
particularly niobium
Metal carbide and metal oxides are reacted in vacuum at elevated temperature so that both oxygen and carbon are removed as carbon monoxide
Name is given because it removes both oxygen and carbon
simultaneously
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Powder Characterization & Testing

Economical manufacturing of P/M parts &
components depends upon the physical & chemical

characteristics of the powders, which in turn depend upon the type of manufacturing method utilized for the production of the metal powders Important to test and verify that powder is suitable for subsequent processing Sampling technique is performed to test the powder
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Powder Conditioning
Metal powders directly after production are generally not suitable further processing as they does not possess favorable physical or chemical properties and thus require powder conditioning, which
involves mechanical, thermal (heat treatment) or chemical treatments or physical alloying (additives as binders) treatments
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Conditioning Methods Used

Preliminary heat treatment in reducing atmosphere or vacuum like annealing , which reduces work-hardening, improves apparent density, decreases oxidation, improves purity, improves pressing (compressibility & compactability) characteristics Blending & mixing (blending is through intermingling of different powders of same composition and material, whereas mixing is the intermingling of powders of different materials)
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Characterization Methods
Chemical composition ( wt analysis or XRD of SEM) Particle size & their distribution ( Sieve Analysis) Particle shape ( SEM) Particle microstructure ( Optical Microscope /SEM) Apparent density Tap/ packed density Flow rate Compressibility & compact ability Green density & porosity Green strength ( Just after compaction before sintering)
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BLENDING OR MIXING
Can use master alloys, (most commonly) or elemental powders that are used to build up the alloys Master alloys are with the normal alloy ingredients Elemental or pre-alloyed metal powders are first mixed with lubricants or other alloy additions to produce a homogeneous mixture of ingredients
The initial mixing may be done by either the metal powder producer or the P/M parts manufacturer
When the particles are blended: Desire to produce a homogenous blend Over-mixing will work-harden the particles and produce variability in the sintering process
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BLENDING POWDERS
Blending powders is the second step in the P/M process

Powders made by different processes have different sizes and shapes and must be well mixed Powders of different metals can be mixed together Lubricants can be mixed with the powders to improve their flow characteristics Fig: Some common equipment geometries for mixing or blending powders. (a) cylindrical, (b) rotating cube, (c) double cone, and (d) twin shell.
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COMPACTION
Usually gravity filled cavity at room temperature
Pressed at 60-100 ksi

Produces a Green compact

Size and shape of finished part (almost) Not as strong as finished part handling concern
Friction between particles is a major factor
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COMPACTION OF METAL POWDERS
Blended powders are pressed together The powder must flow easily into the die
Size distribution is an important fact

They should not be all the same size Should be a mixture of large and small particles
The higher the density the higher the strength
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COMPACTION TOOLING
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COMPACTION CYCLE
1. 2.
3. 4.
5.
6.
Cycle Start Charge die w/powder Compaction begins Compaction complete Ejection of compaction Recharging of die
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ISOSTATIC PRESSING
Because of friction between particles
Apply pressure uniformly from all directions Wet bag (left)

Dry bag (right)
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ISOSTATIC PRESSING
Cold isostatic Pressing (CIP) Metal powder is placed in a flexible rubber mold Pressurized hydrostatically Uses pressures up to 150 KSI Typical application is automotive cylinder liners
Fig: Schematic diagram, of cold isostatic, as applied to forming a tube.The powder is enclosed in a flexible container around a solid core rod.Pressure is applied iso-statically to the assembly inside a 33 high-pressure chamber.
HOT ISOSTATIC PRESSING
Hot Isostatic pressing Container is made of high-meltingpoint sheet metal Uses a inert gas as the pressurizing medium Common conditions for HIP are 15KSI at 2000F Mainly used for super alloy components
Fig: Schematic illustration of hot isostatic pressing.The pressure and temperature variation vs.time are shown in the diagram
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Increased
compaction pressure
Provides better packing of particles and leads to porosity localized deformation allowing new contacts to be formed between particles
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At higher pressures, the green density approaches density of the bulk metal Pressed density greater than 90% of the bulk density is difficult to obtain Compaction pressure used depends on desired density
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Smaller particles provide greater strength mainly due to reduction in porosity Size distribution of particles is very important. For same size particles minimum porosity of 24% will always be there
Box filled with tennis balls will always have open space between balls Introduction of finer particles will fill voids and result in density
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IMPORTANCE OF PUNCH AND DIE MATERIALS
Depends on the abrasiveness of the powder metal

Tungsten-carbide dies are used
Punches are generally made of the similar materials

Dimensions are watched very closly
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OTHER SHAPING PROCESSES
Rolling powder is fed though the roll gap and is used to make coins and sheet metal
An example of powder rolling
Extrusion has improved properties and parts my be forged in a closed die to get final shape Pressure less compaction gravity filled die and used to make porous parts ( Filters) Ceramic molds molds are made by investment casting and the powder is compressed by hot isostatic pressing
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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
Green Compact Product
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Stages in Sintering Process

(a)Adhesion without shrinkage
(diffusion
boundaries)
of
particles
and
formation
of
grain
(b)Densification and grain growth stage (c)Formation of closed pores space
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Mechanism of Sintering Process
(a). Adhesion Mechanism (b). Material Transport Mechanism
(i). Recovery & recrystallization

(ii). Plastic flow (iii). Evaporation & condensation
(iv). Volume diffusion

(v). Surface diffusion (vi). Grain boundary diffusion
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SINTERING
Fig: Schematic illustration of two mechanism for sintering metal powders: (a) solid-state material transport; (b) liquid-phase material transport. R= particle radius, r=neck radius, and (p)=neck profile radius
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SINTERING
Final part properties drastically affected Fully sintered is not always the goal
Example- Self lubricated bushings
Dimensions of part are affected

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Sintering Ctd.
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Liquid Phase Sintering
During sintering a liquid phase, from the lower MP component, may exist
Alloying may take place at the particle-particle interface
Molten component may surround the particle that has not
melted

High compact density can be quickly attained Important variables:
Nature of alloy, molten component/particle wetting, capillary action of the liquid

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SINTERING CTD.
Gases commonly used for sintering: H2, N2, inert gases or vacuum
EXAMPLE
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MECHANICAL PROPERTIES ( Steel Alloys)
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SECONDARY & FINISHING OPERATIONS
To improve the properties of sintered P/M products several additional operations may be used: Coining and sizing compaction operations Impact forging cold or hot forging may be used
metal infiltrates the pores of a sintered part to produce a stronger part and produces a pore free part Other finishing operations
Infiltration
Heat treating Machining Grinding Plating
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Examples of P/M Parts, Showing Poor Designs and Good ones.

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DEFECTS IN PM PRODUCTS
Improper density (green compact) Improper bonding (after compacting & sintering presence of foreign materials) Inhomogeneous properties (improper lubrication)
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DESIGN CONSIDERATIONS FOR P/M
Design principles to consider

Shape of the compact must be simple and uniform Provision must be made for the ejection of the part Wide tolerances should be used when ever possible
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P/M PROCESS CAPABILITIES

Advantages
It is a technique for making parts from high melting point refractory metals
High production rates Good dimensional control
Wide range of compositions for obtaining special mechanical and physical properties
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PROCESS CAPABILITIES
Limitations
High cost Tooling cost for short production runs Limitations on part size and shape Mechanical properties of the part Strength Ductility
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ECONOMICS OF POWDER METALLURGY

Competitive
High
with casting and forging

initial cost for quantities over 10,000 pieces
Economical Reduces
or eliminates scraps
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DIE DESIGN FOR P/M
Thin walls and projections create fragile tooling. Holes in pressing direction can be round, square, Dshaped or any straight-through shape. Draft is generally not required. Generous radii and fillets are desirable to extend tool life.
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ADVANTAGES OF P/M
Virtually unlimited choice of alloys, composites, and associated properties Refractory materials are popular by this process
Controlled porosity for self lubrication or filtration uses Can be very economical at large run sizes (100,000 parts) Long term reliability through close control of dimensions and physical properties Wide latitude of shape and design
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Very good material utilization
DISADVANTAGES OF P/M

Limited in size capability due to large forces
Specialty machines
Need to control the environment corrosion concern Will not typically produce part as strong as wrought product. (Can repress items to overcome that)
Cost of die typical to that of forging, except that design can be more specialty
Less well known process
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FINANCIAL CONSIDERATIONS
Die design must withstand 100 ksi, requiring specialty designs Can be very automated
1500 parts per hour not uncommon for average size part 60,000 parts per hour achievable for small, low complexity parts in a rolling press Larger parts may require special machines (larger surface area, same pressure equals larger forces involved)
Typical size part for automation is 1 cube
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APPLICATIONS OF PM
1.Cemented carbide cutting tools
2.Heavy duty brake pads

3.Magnetic cores for transformers 4.Antifriction bearings 5.Bulb filaments
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EXAMPLE PARTS
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Powder Metallurgy: Porous Metals

Filters
Oil-impregnated Porous Bronze Bearings

nic.sav.sk
www.ondrives.com
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www.hd-bearing.com
Powder Metallurgy: Connecting Rods
www.dps-performance.com
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Forged on left; P/M on right
Powdered Metal Transmission Gear
Warm compaction method with 1650-ton press Teeth are molded net shape: No machining UTS = 155,000 psi 30% cost savings over the original forged part
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AUTOMOTIVE COMPONENTS
1. connected rod with big end cap

2. saddles of inlet and exhaust valves 3. valve spring plate
4. distribution shaft driving pulley 5. strap tension gear roller 6. screw nut 7. fuel pump filter 8. embedding filter
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SUMMARY
Powder
metallurgy can produce products out of

materials that are otherwise very difficult to manufacture P/M products can be designed to provide the targeted
properties
Variations in product size, production rate, quantity, mechanical properties, and cost
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ADVANTAGES AND DISADVANTAGES OF POWDER METALLURGY
Advantages
Elimination or reduction of machining High production rates
Disadvantages
Inferior strength properties High tooling costs High material cost Size and shape limitations Dimensional changes during sintering
Wide variations in compositions

Wide property variations Scrap is eliminated or reduced
Density variations
Health and safety hazards
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CONCLUSIONS
P/M
is a proven technology dating back centuries.
By utilizing 97% original material, cost and energy are minimized Properties and dimensions are easily controlled. Wide variety of P/M applications which are still increasing
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THANK YOU FOR YOUR ATTENTION
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ME-402

POWDER METALLURGY PROCESS

RAMESH KUMAR NAYAK

Ramesh K Nayak, SME, KIIT University

Definition of Powder Metallurgy (P/M)

WHY POWDER METALLURGY ?

BASIC STEPS IN POWDER METALLURGY (P/M)

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

INDUSTRIAL PROCESSING STEPS

Chemical reduction of oxides Electrolytic deposition

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Modified distillation technique

Thermal Decomposition Gaseous

monoxide over spongy or powdered metal at suitable temperature

Electro Deposition from Aqueous Solutions &

Precipitation from Aqueous Solution

Precipitation from Fused Salt

Similar to precipitation from aqueous solution and only difference

Hydrometallurgical / Gaseous Reduction

pressure (400 900 psi) and temperature (130 210 0C)

Oxidation and decarburization

Name is given because it removes both oxygen and carbon

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Powder Characterization & Testing

components depends upon the physical & chemical

Conditioning Methods Used

Blending powders is the second step in the P/M process

Usually gravity filled cavity at room temperature

Pressed at 60-100 ksi

Produces a Green compact

Friction between particles is a major factor

COMPACTION OF METAL POWDERS

Size distribution is an important fact

The higher the density the higher the strength

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Apply pressure uniformly from all directions Wet bag (left)

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

HOT ISOSTATIC PRESSING

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

Ramesh K Nayak, SME, KIIT University

IMPORTANCE OF PUNCH AND DIE MATERIALS

Depends on the abrasiveness of the powder metal

Tungsten-carbide dies are used

Punches are generally made of the similar materials

OTHER SHAPING PROCESSES

Ramesh K Nayak, SME, KIIT University

An example of powder rolling

Ramesh K Nayak, SME, KIIT University

Green Compact Product

Stages in Sintering Process