Powder Metallurgy (P/M)

ME 355 Sp06

Competitive with processes such

as casting, forging, and
machining.
Used when
melting point is too high (W,
Mo).
reaction occurs at melting (Zr).
too hard to machine.
very large quantity.
Near 70% of the P/M part
production is for automotive
applications.
Good dimensional accuracy.
Controllable porosity.
Size range from tiny balls for ballW. Li
1
point pens to parts weighing 100

Basic Steps In Powder

Metallurgy

ME 355 Sp06

Powder Production
Blending or Mixing
Powder Consolidation
Sintering
Finishing

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1. Powder Production

Many methods: extraction from compounds, deposition,

atomization, fiber production, mechanical powder
production, etc.
Atomization is the dominant process

(a)

(b)

(c)

(a) Water or gas atomization; (b) Centrifugal atomization; (c) Rotating elec
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Characterization of
Powders

Size of powders 0.1 um 1 mm

Sieve size quoted as mesh number
Particle D = 15/mesh number (mm)
325 mesh 45 um

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2. Blending or Mixing
Blending a coarser fraction with a finer fraction ensures
that the interstices between large particles will be filled out.
Powders of different metals and other materials may be
mixed in order to impart special physical and mechanical
properties through metallic alloying.
Lubricants may be mixed to improve the powders flow
characteristics.
Binders such as wax or thermoplastic polymers are added
to improve green strength.
Sintering aids are added to accelerate densification on
heating.

ME 355 Sp06

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3. Powder
Consolidation

Cold compaction with 100 900

MPa to produce a Green body.

Die pressing
Cold isostatic pressing
Rolling
Gravity

Injection Molding small, complex

parts.

ME 355 Sp06

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Die pressing

Friction problem in cold

compaction

The effectiveness of pressing with a single-acting punch is

limited. Wall friction opposes compaction.
The pressure tapers off rapidly and density diminishes away
from the punch.
Floating container and two counteracting punches help
alleviate the problem.

ME 355 Sp06

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4. Sintering

Parts are heated to 0.7~0.9 Tm.

Shrinkage always occurs:

Transforms compacted mechanical

bonds to much stronger metallic
bonds.

Vol _ shrinkage
ME 355 Sp06

Vsintered
Vgreen

green

sintered
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green
Linear _ shrinkage
sintered

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5. Finishing

The porosity of a fully sintered part is still significant (4-15%).

Density is often kept intentionally low to preserve
interconnected porosity for bearings, filters, acoustic barriers,
and battery electrodes.
However, to improve properties, finishing processes are
needed:
Cold restriking, resintering, and heat treatment.
Impregnation of heated oil.
Infiltration with metal (e.g., Cu for ferrous parts).
Machining to tighter tolerance.

ME 355 Sp06

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Special Process: Hot

compaction

Advantages can be gained by combining consolidation and

sintering,
High pressure is applied at the sintering temperature to bring
the particles together and thus accelerate sintering.
Methods include
Hot pressing
Spark sintering
Hot isostatic pressing (HIP)
Hot rolling and extrusion
Hot forging of powder preform
Spray deposition

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Process Capabilities
Contional

HIP

Injection
Molding (IM)

Precision IM

Preform
Forging

Metal

All

All (SA,
SS)

All (Steel, SS)

All

Steel, SA

Surface detail

B-C

Mass, kg

0.01-5(30)

0.1-10
10-7000 (e)

0.01-0.2

0.005-0.2

0.1-3

Min. section, mm

1.5

0.1

Min. core diam. mm

4-6

0.2

Tolerance +/-%

0.1

0.3

0.1

0.25

Throughput (pc/h)

100-1000

5-20

100-2000

100-2000

200-2000

Min. quantity

1000-50,000

1-100

10,000

10,000

100,000

Eq. Cost

B-C

A-B

A-B

A-B

A: highest, B: median, C: lowest

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Design Aspects

(a) Length to thickness ratio limited to 2-4; (b) Steps limited to avoid density variation;
(c) Radii provided to extend die life, sleeves greater than 1 mm, through hole greater
than 5 mm; (d) Feather-edged punches with flat face; (e) Internal cavity requires a draft;
(f) Sharp corner should be avoided; (g) Large wall thickness difference should be avoided;
(h)355
Wall
thickness should be larger than 1 mm.
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Advantages and Disadvantages

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.
Very good material utilization.
Limited part size and complexity
High cost of powder material.
High cost of tooling.
Less strong parts than wrought ones.
Less well known process.

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