METALURGIJA PRAHA (PM)

Prof. dr. sc. Boidar Matijevi

Fakultet strojarstva i brodogradnje
Zavod za materijale

KALIBRIRANJE
Kalibriranjem je mogue poveati ili smanjiti dimenzije obratka
primjenom matrice ili trna tj. kalibriranjem
Tvrdoa dijelova koji se kalinbriraju nakon sinteriranja mora biti >180 HV

KLASIFIKACIA ELIKA ZA SINTERIRANJE PREMA

POROZNOSTI

USPOREDBA SLOENOST OBLIKA : GUSTOA PM

DIJELOVA PM POSTUPAKA

USPOREDBA TONOST DIMENZIJA : GUSTOA PM

DIJELOVA PM POSTUPAKA

USPOREDBA TROKOVI : GUSTOA PM DIJELOVA PM

POSTUPAKA

Tvrdi metal
Sastav i svojstva:
WC visoka tvrdoa
Co vrstoa
TiC, TaC, NbC
poveanje tvrdoe i
otpornosti na visoke
temperature pri radu

Svojstva tvrdog metala

(primjer za K-vrste)
Veliina
zrna WC
m

ISO
oznaka
TM

WC
%

Co
%

g/cm3

K-10

94

15,0

1650

1500

Fina

K-20

94

15,0

1550

1700

Srednja

1,5

K-30

91

14.7

1500

2000

Srednje
gruba

2,5

Tvrdoa ilavost
HV
N/mm2

Struktura

Tehnoloki proces proizvodnje

WC

TiC

TaC

Co

M LJEVENJE

SUENJE

PARAFINIRANJE

GRANULIRANJE

PREANJE

PREDSINTERIRANJE
OBLIKOVANJE

SINTERIRANJE

NAKNADNA
OBRADA

LEM LJENJE

BRUENJE

PROFILNO
BRUENJE

POLIRANJE

Proizvodi od tvrdog metala

Nain dobivanja
Mijeanje metalnih
prahova meusobno s
plastifikatorom
Preanje
Sinteriranje

Primjena
Alati za obradu
skidanjem strugotine
Alati za obradu stijena
i kamena
Konstrukcijski dijelovi
otporni na troenje

Proizvodi od tvrdog metala

rezne ploice
alati s ploicama od
tvrdog metala

Proizvodi od volfram bakra

Od volfram bakra izrauju se

kontaktni materijali i to na dva
naina:
Iz mjeavine W i Cu
Natapanjem volframa s
bakrom
Zbog svojih svojstava W-Cu se
primjenjuje:
Za visokonaponske kontaktne
materijale
Za elektrode za zavarivanje i
erodiranje

Proizvodi od volfram bakra

Svojstva W-Cu
Sastav

g/cm3

Tvrdoa
HV

El.vodljivost
m/mm2

W-Cu 80/20

min 15,2

210

16-20

W-Cu 75/25

min 14,6

180

17-21

W-Cu70/30

min 13,9

160

18-22

Proizvodi od sinter bronce

Legura bakra i kositra
sastava 90/10 te. %,
sferinog oblika (moe
biti razliite granulacije)
Glavna karakteristika
gotovog proizvoda je
definirani porozitet pa se
koristi za proizvodnju
filtera i priguivaa buke

KONSTRUIRANJE SINTERIRANIH DIJELOVA

PROVRTI
Otvori u smjeru kompaktiranje mogu biti okrugle, D oblika ukljuujui oblik
kljuanjice, zatvorene krivulje itd. Dijelovi alata za kompaktiranje za oblikovanje
rupa nazivaju se jezgre.
Jezgre moraju imati odgovarajuu vrstou I ne smiju se izvijati tijekom
kompaktiranja ili izbacivanja zelenog otpreska
Provrti za olakavanje komada esto se dodaju velikim komadima da bi se
smanjila povrina stlaivanja I tako imali dijelove povoljnije za kompaktiranje te
manje teine
Slijepe rupe, slijepi pragovi u rupama I konine rupe jednostavno se proizvode
Poprene rupe rade se nakon operacije sinteriranja, majee strojnom
obradom

DEBLJINA STJENKE
Punjenje kalupa je najvanije pravilo, ne konstruirati debljinu stjenke tanju od
1, 52 mm (0,060 in.)
Izbjegavati duge, tanke stjenke; one zahtjevaju alate koji su lomljivi a takoer i
dijelovi sami imaju tendenciju postizanja razliitih gustoa
Gdje je odnos duine prema debljini stijenke 8:1 ili vie, posebni preduvjeti
moraju se postii da bi postigli jedolino punjenje a razlike u gustoi bile male.

RAVNE PLOHE
Ukupna izmjerena ravnina zavisi od debljine dijela i povrine
Tanki dijelovi skolni su deformaciji vie nego deblji tijekom sinteriranja ili
toplinske obrade
Ponovno (dvostruko) kompaktiranje poboljava ravnou
Ispupenja na ravnim plohama se izrauju jednostavnije nego vee ravne plohe

PRIJELAZI I RADIJUSI
Uglavnom blagi prijelazi su iz vie razloga poeljni:
Alati s blagim prijelazima s radijusima su ekonominiji i trajniji su
Dijelovi s izdanim (velikim) radijusima lake i bre se izrauju
Dijelovi s blagim prijelazima imaju veu homogenost strukture

SKOENJA I KONUSI
Skoenja, povoljnjije nego radiusi, potrebni su na rubovima. Npr. na ahuri,
skoenje od 30 - 40 i 0,13 038 mm vjenca eliminira otar kut i preporuljiv
je nain u praksi kod konstukcije PM dijelova.
Skoenja s velikim kutom mogu se dobiti konusima na alatima ili jezgrama.
Brzina kompaktiranja mora biti manja s ovakvim alatima da bi se izbjegao
problem povezivanja praha i alata tj. kalupa.

KONUSI
Konus je lijeb oko rupe za glavu vijka ili klina. Kada se konus oblikuje
pomou iga, za izbjegavanje okrhnua (pucanja) otroga ruba iga
potrebno je nainiti vijenac visine 0,25 mm

UTORI I LIJEBOVI
ljebovi se mogu dobiti na oba kraja dijela pomou iga uz slijedea
upozorenja:
Zakrivljeni ili poluokrugli lijebovi su ogranieni na max. 20% ukupne duine
komada
Pravokutni lijebovi su ogranieni do max. 15% ukupne duine dijela,
omoguujui da povrina paralelna na smijer stlaivanja ima do 12 skoenje
I da su svi kuteve izvedeni s radiusom
Duboke i uske lijebove treba izbjegavati zboh oteenja alata (lomljenja
okrhnua)

UTORI
Utori na horizontalnoj ravni (okomito na smijer stlaivanjakompaktiranja) ne mogu se dobiti kompaktiranjem jer oni sprjeavaju
izbacivanje dijela iz alata.
Kruni prstenovi- utori mogu se dobiti strojnom obradom kao drugom
operacijom.

TOLERANCIJE
Tolerancije kojih se drimo kod konstruiranja dijelova koje se proizvode
PM tehnologijom usporedive su s tolerancijama za dijelove koji se
izrauju drugim tehnologijama.

PREPORUKE ZA KONSTRUIRANJE DIJELOVA KOJI SE

IZRAUJU PM TEHNOLOGIJOM

ZUPANICI

PRIMJERI PRAVILNO I POGRENO

KONSTRUIRANIH DIJELOVA

Why PM?
The PM process provides a host of advantages over competing metalworking
technologies. These all add up to cost-effectiveness, shape and material flexibility,
application versatility, and part-to-part uniformity
for improved product quality.
Advantages of the PM Process
Eliminates or minimizes machining by producing parts at, or close to, final
dimensions
Eliminates of minimizes scrap losses by typically using more than 97% of the
starting raw material in the finished part
Permits a wide variety of alloy systems
Produces good surface finishes
Provides materials which may be heat-treated for increased strength or increased
wear resistance
Provides controlled porosity for self-lubrication or filtration
Facilitates manufacture of complex or unique shapes which would be impractical
or impossible with
other metalworking processes
Is suited to moderate- to high-volume component production requirements
Offers long-term performance reliability in critical applications
Is cost-effective

Case Study 1
Component: Main Bearing Cap for Automobile Engines
Process: PM
Weight: 0.755 kg (1.66 lb.)
Alloy: Proprietary Steel
Tensile Strength: 450 MPa (65,000 psi)
Elongation: 3%
Apparent Hardness: 70 HRB
Density: 6.6 g/cm (0.24 lb./in.)
Fatigue Endurance Limit: 160 MPa (23,000 psi)
Secondary Operations: Machining
Alternative Process: Nodular Iron Casting
Annual Production: > 6,000,000
Description:
This main bearing cap (MBC) is used in General Motors 3100 V-6 and 3800 V-6 engines. The 3100 engine contains three
caps weighing about 2.2 kg (5 lbs.) and the 3800 engine contains four caps weighing 3.6 kg (more than 8 lbs.).
Bolted to the engine block, main bearing caps guide and retain the engine crankshaft which must be held securely in place
but turn freely. The crankshaft withstands the full combustion and inertia loads of the engine.
The MBC is attached to the engine block with bolts through long bolt holes which also locate the cap along the front/rear axis
of the engine. The part is press fit into a channel in the block which requires it to have an accurate width feature for a
consistent press fit. An installation profile to ensure smooth fitting to the block is formed on the outer edges of the cap when it
is produced. The joint faces must be flat to ensure solid contact with the block. The surface directly under the bolt head must
be flat and parallel to ensure uniform pressure at the high clamp loads used. There is a notch in the arch of the cap which
locates the bearing shells in place.
The statistically held tolerance along the snap-width that engages the engine block channel is 0.051 mm (0.002 in.). The
flatness of the joint faces is held to 0.051 mm (0.002 in.) individually and 0.101 mm (0.004 in.) when considered as a single
plane. Because the cast-iron engine block and the PM cap are machined simultaneously during crankshaft diametral boring,
the PM and cast-iron radii must match. This requires close control of the radial height and the horizontal radius to 0.254 mm
(0.010 in.).
MBCs made from gray cast iron, the competitive material, are cast into a sand mold to produce a "loaf," which required
broaching, drilling, spot facing, and milling before the loaf is cut into individual MBCs. This process produces a 60% yield of
main bearing caps from the cast-iron loaf.
PM provided the necessary fatigue strength, quality, machinability, and economy of a near-net-shape design.

Case Study 2
Component: Auto Transmission Sprockets
Process: PM
Size: OD drive: 90100 mm (3.543.93 in.)
OD driven: 100106 mm (3.934.17 in.)
Weight: Drive: 450590 g (11.3 lb.)
Driven: 505570 g (1.11.26 lb.)
Alloy: Steel
Tensile Strength: 860 MPa (125,000 psi)
Yield Strength: 830 MPa (120,000 psi)
Elongation: 1.5%
Apparent Hardness: 60 HRC
Density: 7.8 g/cm ( 0.28 lb./in.), surface density
7.0 g/cm (0.25 lb./in.) core density
Heat Treatment: Vacuum Carburizing
Secondary Operations: Densifying Teeth and Journal, Precision Grinding and Polishing Journal
Alternative Process: Gear Hobbing
Annual Production: 2,000,000
Description:
High-performance PM steel automatic transmission sprocketsone drive and one drivenare compacted, sintered, and
selectively densified. The teeth and journal are further densified by a cold-working process and then vacuum carburized, producing
a precisely controlled case on the critical journal and tooth flank surfaces. This provides high strength and exceptional bearingand tooth-surface durability.
The journal bearing-surface durability exceeds carburized wrought 8620 steel and is equivalent to 52100 bearing steel.
The surface density of the parts is typically 7.8 g/cm, gradually falling to lower levels towards the core. The core regions are not
highly stressed and remain at a density of 7.0 g/cm. The rolling-contact fatigue limit of the journal is 4,000 MPa (580,000 psi).
There are two components in a set in each transmission that transmit power from the engine to the transmission via a silent chain.
There are three ratios, each with a drive sprocket and a driven sprocket.

Case Study 4
Component: Transmission Torque-Converter Hub
Process: Warm Compacting
Size: 101.6 mm (4 in.) dia x 50.8 mm (2 in.) high
Weight: 1.22 kg (2.7 lb.)
Alloy: PM Steel
Tensile Strength: 810 MPa (117,000 psi)
Yield Strength: 430 MPa (62,000 psi)
Elongation: 3%
Apparent Hardness: 17 HRC
Density: 7.2 g/cm (0.26 lb./in.)
Fatigue Endurance Limit: 240 MPa (35,000 psi)
Secondary Operations: 240 MPa (35,000 psi)
Alternative Process: Machining and Forging
Annual Production: 200,000
Description:
The complex multi-level torque-converter hub operates in a high-output automotive transmission. It transmits high enginetorque levels to the transmission through internal and external as-molded splines.
The hub is formed using a special warm compaction system for powder in a 7.3 MN (825 ton) compacting press. Warm
compaction combined with a high-performance diffusion alloy powder allowed PM to replace a machined and heat-treated
forged part at a cost savings of more than 30% and an assembly savings of more than 50%.
The transmission functions in 6.8 L and larger engines that go into trucks, vans, and large sport utility vehicles (SUV).
The part has a minimum density of 7.2 g/cm, a tensile strength of 810 MPa (117,000 psi), a yield strength of 430 MPa
(62,000 psi) and a fatigue limit of 240 MPa (35,000 psi). Subjected to severe durability testing, the hub must withstand an
internal spline torque of 1,210 N-m (890 ft.lbs.) for one million cycles. Several hubs were tested to two million cycles with the
part finally failing at nine million cycles. The spline meets a tolerance of 0.13 mm (0.005 in.) and machined diameters meet a
tolerance of 0.05 mm (0.002 in.).

Case Study 6
Component: Receiver, Clevis End, and Articulating Link for Endoscopic Surgical Tool
Process: MIM
Size: Receiver68 mm (2.7 in.)
Clevis End28 mm (1.1 in.)
Articulating Link7.5 mm (0.3 in.)
Weight: Receiver11 g (0.024 lb.)
Clevis End7 g (0.015 lb.)
Articulating Link0.097 g (0.0002 lb.)
Alloy: 17-4 PH Stainless Steel
Tensile Strength: 1,180 MPa (170,000 psi)
Yield Strength: 1,100 MPa (160,000 psi)
Elongation: 3%
Apparent Hardness: 36 HRC
Density: 7.5 g/cm (0.27 lb./in.)
Secondary Operations: Sizing and Heat Treating
Annual Production: 30,000
Description:
Three intricate 17-4 PH stainless steel parts made by metal injection molding (MIM) are used in a surgical toolan
articulating endoscopic stapler.
Formed very close to their final shape, these thin-walled parts are heat treated and have an ultimate tensile strength of
1,180 MPa (170,000 psi), a yield strength of 1,100 MPa (160,000 psi), a 36 HRC hardness, an elongation of 3%, and a
density of 7.5 g/cm.
The parts adhere to precision tolerance requirements. The receiver has a 0.71 mm (0.028 in.) wall section which forms a
slot held to 8.698.79 mm (0.3420.346 in.) over the entire length. The clevis holds a roundness of 11.7 mm 0.05 mm
(0.460 in. 0.002 in.) on a 0.864 mm (0.034 in.) wall section. The link holes are held to 1.19 mm 0.019 mm (0.047
0.00075 in.).
The receiver is thin walled with a required varying wall section over a length of 50.8 mm (2 in.). The clevis has a thin wall of
0.711 mm (0.028 in.).
The endoscopic device combines a 45 bilateral articulation with a 360 rotation, providing excellent maneuverability and
tissue access for endoscopic procedures such as appendectomies, lung resections, colectomies, splenectomies, and
nephrectomies.

Case Study 7
Component: Diesel Engine Valve Lifter
Process: HIP Cladding
Size: 82.55 mm (3.25 in.) long x 35 mm (1.4 in.)
diameter at face
Weight: 204 g (0.45 lb.)
Alloy: Tungsten Carbide Face and Steel Shaft
Density: 100% at bond surface
Secondary Operations: Grinding on Face Only,
Finish Machine Stem
Alternative Process: Furnace Brazing
Annual Production: 400,000
Description:
A HIP-clad valve lifter used in a full range of medium- to heavy-duty truck diesel engines replaced a furnace brazed part,
offering a higher-quality bond, a drastic reduction in scrap, and no field failures. The wear face of the valve lifter rides on
the camshaft, opening and closing the engine valves.
The HIP-clad product consists of a 9% Co-bonded tungsten carbide (WC) face, made from powder and pressed and
sintered; a steel sheet metal cap fitted over the WC disk; a copper-alloy foil interlayer; and a steel shaft. The steel cap is
electron-beam welded to the steel shaft and then hot isostatically pressed to provide a very strong 100% bond. The
HIPing takes place at 1,010C (1,850F) at a pressure of 100 MPa (15,000 psi).
The tungsten carbide face has a density of 14.5214.72 g/cm, a hardness of 90.8 5 HRA, and a transverse rupture
strength of 2,450 MPa minimum (355,000 psi).
Secondary operations are limited to grinding the face to remove the sheet metal cap and exposing the high-wearresistant tungsten carbide face. The steel cap is left on the edge surface to prevent damage during assembly.

Case Study 8
Component: Connecting Rod for Automobile Engine
Process: P/F
Weight: 0.75 kg (1.65 lb.) as-forged
0.66 kg (1.45 lb.) finished
Alloy: Copper-Steel (MPIF FC-0205)
Tensile Strength: 760 MPa (110,000 psi)
Yield Strength: 550 MPa (80,000 psi)
Hardness: 24 HRC
Density: 7.84 g/cm (0.283 lb./in.)
Relative Density: 99.6%
Secondary Operations: Deflashing, Shot Peening and Finish Machining
Alternative Process: Precision Forging
Annual Production: > 2,000,000
Description:
The P/F connecting rod is used on a growing number of passenger car engines. P/F produces rods with mechanical
properties equivalent to those of conventional precision forging. For example, the mean endurance limit is 275 MPa (40,000
psi) with a standard deviation of less than 5%. This value is 153% of the stress level when the engine is operating at the
maximum functional design loads. The high level of fatigue performance is achieved by forging to 99.6% of relative density,
virtually eliminating microporosity, and by maintaining a high level of powder purity.
P/F also produces rods with much closer tolerances than their precision forged counterparts. For example, dimensional
variation on the outside profile of the rod is held to 0.12 mm (0.005 in.) compared with 0.5 mm (0.020 in.) for conventional
precision-forged rods. There are similar advantages in straightness and elimination of surface defects. The dimensional
precision achieved by P/F eliminated a broaching operation on the bolt bosses. A minimal balancing pad is provided on the
rod end, and no balancing pad is required on the pin end. The cap is fractured from the rod, eliminating saw cutting, face
grinding and line reaming operations that are normally required. The fracturing operation leaves very fine mating irregularities
in the rod and cap, which locate the members securely during reassembly and eliminate the tendency to shift in service.
The rods also display a uniform microstructure with a structural integrity that has eliminated the need for nondestructive test
procedures such as magnetic particle inspection.

Case Study 9
Component: Needle-Biopsy-Gun Components
Process: MIM
Weight: From 118 g to 1.15 g
Alloy: 316L Duplex Stainless Steel
Tensile Strength: 503 MPa (73,000 psi)
Yield Strength: 290 MPa (42,000 psi)
Elongation: 40%
Apprent Hardness: 7080 HRB
Density: 7.6 g/cm min.
Secondary Operations: From CNC Machining
to none
Annual Production: 10,000 of each part
Description:
Eleven 316L duplex stainless steel parts fabricated by metal injection molding are assembled by the customer along
with 2 rods, 4 pins, and 2 screws to produce this reusable "needle-biopsy gun." The gun is loaded with a disposable
needle cartridge at the hospital. The needle is inserted into the target, usually while the patient is being scanned.
When the gun is fired, the inner and outer needles move forward in a manner that collects a tissue sample from the
target area that can then be withdrawn for having a biopsy done.
Of the eleven MIM components only the large "housing" requires CNC machining to remove some sintering supports
that are molded into the part to minimize distortion. The two "thumb knobs" have molded-in sintering supports as well
but they are located on hidden surfaces and can be broken off. The "fixed lid" is given a serialized number for
finished product identification.
The MIM component supplier and the customer teamed up to minimize the time to get initial production quantities
and establish function-driven specifications.

Case Study 10
Component: Automatic- Tramsmission Oil Pump
Process: PM Assembly
Weight: PM slide 245 g, PM rotor 178 g,
PM lid 545 g, PM body 495 g
Alloy: SlideFC-0205, other partsFC-0208
Tensile Strength: 50/60 ksi
Elongation: Less than 1%
Apprent Hardness: Steam-Treated Surface
HRB 85, Rotor SplineHRA 70
Secondary Operations: Double-Disc Grinding
Alternative Process: Cast and Machine
Annual Production: 1,000,000
Description:
This oil pump is supplied to General Motors as a complete stand-alone component, ready to install in their 4T40 frontwheel-drive automatic transmission. It is the world's first non-select-fit, high-volume transmission oil pump. Previous
automatic pump designs employ cast-iron or aluminum housings and lids. The housing pump pocket would be machined
to a typical tolerance of .050 mm, necessitating the use of select-fit pump components to maintain the clearance required
for good pump performance.
The net-form capability of powder metallurgy, combined with grinding the length and parallelism of each component to
tolerances of less than .010 mm, provides a low-cost, efficient, and reliable oil pump that eliminates the requirement to
select-fit during assembly.
Eliminating the select-fit operation improves the overall efficiency of the pump, reduces the amount of inventory in the
system, and reduces the cost of the assembly operation.
Transmission pumps also typically require two powder metal pumping components. This design employs a total of 4 PM
parts: rotor, slide, body, and lid. All parts are steam treated for improved wear resistance, and the rotor spline is induction
hardened.

Case Study 11
Component: Planetary Gear Set (including): Carrier Plate, Planetary Pinions, Ring Gear, Spur/Sun Gear

Process: PM
Alloy: Planetary Ring GearFLNC 4408-90HT
Spur/Sun GearFN 0205-105HT
Tensile Strength: Planetary Ring Gear690 MPa (100,000 psi);
Spur/Sun Gear830 MPa (120,000 psi)
Yield Strength: Planetary Ring Gear620 MPa (90,000 psi);
Spur/Sun Gear720 MPa (105,000 psi)
Apparent Hardness (all parts): 30 HRC
Density (all parts): 6.95 g/cm (0.251 lb./in.)
Heat Treament: Sinter Hardened
Secondary Operations: A proprietary plating process is used eliminating the need for resin impregnation for porosity
sealing which withstands >200 hour salt spray tests without signs of corrosion.
Alternative Process: Machined component systems
Annual Production: >60,000
Description:
This innovative functional assembly of a planetary gear set is used in an automatic latch system for a motorized tailgate in
the Ford Freestar and Mercury Monterrey vehicles. The only non-PM components are a push nut and the cinch shaft. The
custom involute tooth geometry is designed to result in an extremely quiet-running gear set. The use of sinter-hardened
material simplifies manufacture and has excellent wear resistance and strength. The gears meet AGMA quality level 78
with a minimum of distortion. Each assembly is verified for functionality and appearance characteristics.
This product represents a cost savings of 50% over conventionally fabricated assemblies.