Powder Metallurgy (P/M)

Method:
Make fine metal powders and sort
Mix powders to get alloy
Iron alloys most common, also Bronze
Compaction
Powder is pressed into a green compact
20,000-100,000psi pressure
Still very porous, ~70% density
May be done cold or warm (higher density)
Sintering
Controlled atmosphere: no oxygen
Heat to .75*Tmelt
Particles bind together
Part shrinks in size
Density increases, up to 95%
Strength ~=~ Density

P/M net-shape gears are common, save machining time

P/M (vs. Casting):

Mass produce small steel parts, net-shape
Less waste
Unusual alloys
Range of densities, porosity (adv or disadv)
Less energy use
But: Smaller parts and less complexity (2.5D)

oee.nrcan.gc.ca

Powder Metallurgy
Slightly porous appearance is common

Range of particle sizes

www.buau.com.au

www.parmaco.com

Cermet cutting inserts for lathe

Powder Metallurgy:
Cermet cutting tools
(Ceramic-Metal composite)
www.kyocera-yashica.com.br

Microstructure: ceramic particles in metal matrix

Cermet-tipped saw blade for long life

www.moldmakingtechnology.com
www.toolbarn.com

Metal filters

Powder Metallurgy:
Porous Metals

Oil-impregnated Porous Bronze Bearings

nic.sav.sk

www.ondrives.com

www.hd-bearing.com

Powder Metallurgy: Connecting Rods

www.dps-performance.com

Forged on left; P/M on right

Powdered Metal Transmission Gear

www.chipm.com

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

Powdered Metal Turbine blade-disk (blisk): 1 piece!

www.ml.afrl.af.mil

Conventional Forging vs. Forging of Powdered Metal blank (2nd op)

DeGarmo

References
DeGarmo: E.P. DeGarmo et al, Materials and Processes in
Manufacturing, Wiley, 2003.