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    An Introduction To Powder Metallurgy (PM) : Joseph Tunick Strauss

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    JM Ldg
    PM involves consolidating metal powders into dense parts through pressing and sintering. The document discusses: I. What PM is and why it's used, including lower cost and ability to make complex/composite parts. II. A brief history of PM from ancient times to modern rapid manufacturing. III. The science of PM including powder production via atomization, consolidation through pressing, and sintering to achieve densification and properties. IV. Net shape PM processes like die compaction and metal injection molding for complex parts, as well as powder forging for strength. V. Near-net shape processes like HIP, extrusion and thermal spray to produce preforms for

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    An Introduction To Powder Metallurgy (PM) : Joseph Tunick Strauss

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    52 views65 pages
    PM involves consolidating metal powders into dense parts through pressing and sintering. The document discusses: I. What PM is and why it's used, including lower cost and ability to make complex/composite parts. II. A brief history of PM from ancient times to modern rapid manufacturing. III. The science of PM including powder production via atomization, consolidation through pressing, and sintering to achieve densification and properties. IV. Net shape PM processes like die compaction and metal injection molding for complex parts, as well as powder forging for strength. V. Near-net shape processes like HIP, extrusion and thermal spray to produce preforms for

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    PM involves consolidating metal powders into dense parts through pressing and sintering. The document discusses: I. What PM is and why it's used, including lower cost and ability to make complex/composite parts. II. A brief history of PM from ancient times to modern rapid manufacturing. III. The science of PM including powder production via atomization, consolidation through pressing, and sintering to achieve densification and properties. IV. Net shape PM processes like die compaction and metal injection molding for complex parts, as well as powder forging for strength. V. Near-net shape processes like HIP, extrusion and thermal spray to produce preforms for

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    © All Rights Reserved
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    52 views65 pages

    An Introduction To Powder Metallurgy (PM) : Joseph Tunick Strauss

    Uploaded by

    JM Ldg
    PM involves consolidating metal powders into dense parts through pressing and sintering. The document discusses: I. What PM is and why it's used, including lower cost and ability to make complex/composite parts. II. A brief history of PM from ancient times to modern rapid manufacturing. III. The science of PM including powder production via atomization, consolidation through pressing, and sintering to achieve densification and properties. IV. Net shape PM processes like die compaction and metal injection molding for complex parts, as well as powder forging for strength. V. Near-net shape processes like HIP, extrusion and thermal spray to produce preforms for

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    An Introduction to

    Powder Metallurgy
    (PM)
    Joseph Tunick Strauss
    HJE Company, Inc.

    An Introduction to Powder Metallurgy (PM)


    I
    What is PM and Why is it Used
    II History of Powder Metallurgy
    III General Summary of the Science of PM
    IV Net Shape PM Manufacturing Processes
    Press and Sinter
    Powder Forging (PF)

    Metal Injection Molding (MIM)


    Rapid Manufacturing

    Near Net Shape/Bulk PM Processes


    HIP/CIP (Hot/Cold Isostatic Pressing)
    Powder Rolling, Extrusion,
    Spray Forming, Thermal Spray

    I What is PM and Why is it Used?

    PM is the use of metal powders in industrial


    applications

    PM: The use of metal (or ceramic) powders in


    industrial applications
    Consolidation into dense parts & shapes
    Structural / machine parts
    Cutting tools
    Oil impregnated bushings, filters

    Fusion / Welding
    Solder and brazing pastes
    Welding and thermal spray
    Dental Amalgams
    Rapid Manufacturing

    Other
    Conductive Inks
    Chemical
    Agricultural
    Food and pharmaceuticals

    I What is PM and Why is it Used?

    Casting, Forging, Machining,


    Powder Metallurgy
    Which method to choose?
    Quality, Quantity, Tolerance,
    Geometry, Material, Environment,
    Labor quantity, Skill level, Equipment,
    etc

    LOWEST

    COST!

    Why PM?

    Cost advantage
    Lower manufacturing costs

    Only option

    Cemented Carbides
    Filters, bushings
    Diamond tools
    Composites

    Better properties
    Ni-based superalloys

    I What is PM and Why is it Used?

    I Introduction (cont.)

    POWDER METALLURGY (PM):

    Full-scale Industrialization in past 50 years

    >$2.5 Billion per year in North America

    P/M Processing has Shown Continuous Annual


    Growth for the Past 50 Years by
    1) Replacing Existing Technologies
    2) "DFM: Designed for Manufacturability"
    Keep in mind that powder cost more than equivalent
    cast or wrought material

    II History of PM

    30,000 years ago: Cave paintings


    3000 BC: Egypt/Africa iron implements
    300 AD: India Delhi Column
    1700: France, LPS Pt
    1829: UK, Wollaston Pt: Press, sinter, forge
    1900: Ni powder as catalysts
    1910: US, Coolidge process for tungsten
    1920s: Germany, Cemented carbides
    1920s: Porous parts for self-lubricating bearings, filters
    1920s: Inductor cores from iron powder
    1930s: Press and sinter oil pump gears
    1970s: MIM (Metal Injection Molding)
    2000s: Rapid Manufacturing with metal powder

    III Summary of the Science of PM

    PM consists of three fundamental steps:

    A) Powder Production
    B) Powder Consolidation
    C) Sintering

    III Summary of the Science of PM

    II General Summary of The Science of PM

    A) Powder Production
    Atomization

    Chemical, reduction
    Carbonyl process
    Oxide reduction

    Electrolytic, precipitation
    Mechanical

    III Summary of the Science of PM


    II General Summary of The Science of PM

    A) Powder production by Atomization:


    Disintegration of liquid stream by a second fluid

    Gas Atomization:
    Spherical powder particles
    Good "flowability"

    Water Atomization:
    Irregular powder particles
    Good compactability

    Atomization Schematics
    Water Atomization

    Water

    Induction Coil

    Water

    Gas Atomization

    Schematic of
    Gas atomization system

    Gas Atomized
    Silver Alloy

    Schematic of a
    water atomization
    System

    Water
    Atomized
    Powder

    III Summary of the Science of PM

    Other powder production methods:


    Reduction, reaction, precipitation, and electrolytic
    Fe2O3 (s) + 3H2 (g) 2Fe (s) +3H2O (g)
    Fe(CO)5 (g) + catalysis Fe (s) + 5CO (g)
    Ni(CO)4(g) Ni(s) + 4CO(g)

    Ni (s) + Al (s) NiAl (s)


    2AgNO3 (aq) + 2K2SO3 (aq) 2Ag (s) + K2SO4 (aq) + 2K2NO3 (aq)
    SO2 (aq)
    Cu++ + 2e Cu (s)

    Mechanical: Milling

    Powder Characteristics

    Particle size and size distribution


    Particle shape
    Physical properties
    Hardness and Ductility

    Chemical
    Composition, reactivity, and impurities

    Bulk properties
    Flow properties, apparent density, tap density,
    compressibility, and green strength

    III Summary of the Science of PM

    Materials processed via Powder Metallurgy:


    Conventional:
    Ferrous alloys, stainless steels, Cu, Al, WC/Co
    Specialty:
    Superalloys, tool steels, refractory metals,
    Be, Ti, precious metals, MMC (Metal Matrix Composites)

    III Summary of the Science of PM

    II General Summary of The Science of PM

    B) Powder Consolidation
    Impart shape to net or near net to powder mass
    Net Shape:

    Die Compaction
    MIM (Metal Injection Molding)
    Rapid Manufacturing
    Near Net Shape:
    HIP/CIP (Hot/Cold Isostatic Pressing)
    Hot Pressing
    Extrusion
    Rolling
    Thermal Spray

    III Summary of the Science of PM

    C) Sintering: Heat treatment to promote metallurgical integrity

    Metallurgical bonding of powder particles


    Solid state diffusion
    Liquid phase

    Thermal activated event


    Atomic transport
    Particle rearrangement
    Particle growth, pore elimination

    Results
    Densification, yield useful physical properties (UTS, YS,
    ductility, impact strength, and fatigue strength)

    III Summary of the Science of PM

    III Summary of the Science of PM

    Sintering Furnaces:
    Continuous or Batch
    Controlled Atmosphere:
    inert, reducing, vacuum
    Precise temperature control
    Cost-intensive operation

    IV Net Shape Processing:


    Direct process to final shape
    Eliminate manufacturing operations
    "Chipless" manufacturing,
    Low waste/scrap

    IV Net Shape Processes

    Die Compaction

    Use water atomized powder (irregular shape)


    Rigid tooling: tool steel, WC/Co
    Pressures up to 60 tons/square inch
    Production > 10,000 parts
    High tolerance, 0.001 "/" possible
    High productivity
    Controlled porosity, density (85% to 90%)

    Axis-symmetric
    No undercuts
    No off-axis attributes
    L/D <5

    IV Net Shape Processes


    III PM Manufacturing Techniques

    MIM (Metal Injection Molding)

    Plastic Injection Molding + Powder Metallurgy (PM)

    Complex Shapes
    High density metal parts (> 95%)
    Economy of Scale (high productivity)
    Good tolerance, .003 "/" possible, .005-.008 "/" typ.
    Competes with investment casting
    and discrete machining

    >
    >

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    >>>

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    >>>>>

    IV

    Applications, General Case Studies:


    Orthodontia Brackets
    MIM vs. Discrete Machining and Investment casting:

    Elimination of all (most) machining operations


    Better material utilization (no chips, sprues, etc)
    Able to produce smaller parts than investment cast
    Able to produce more complex geometries than machining
    Massive reduction in labor and labor quality

    IV Net Shape Processes


    III PM Manufacturing Techniques

    Powder Preform Forging

    Press & Sinter + Close die forging

    Less complex shapes than P&S


    High density metal parts (> 99.5%)
    Economy of Scale (high productivity)
    Good tolerance, .001 "/" possible, weight tolerance
    Closed-die Flashless forging

    Necessary for ultimate dynamic properties

    Schematic of Powder Preform Forging

    PM Press-Sinter-Forge vs. Power Forge

    Better material utilization


    Fewer tool sets
    Reduction of secondary machining operations

    Large end bearing bore and mating flats


    Eliminate balancing

    518-792-8733

    IV Net Shape Processes


    Introduction, History

    Rapid Manufacturing:
    1) CAD (Computer Aided Design) representation of the part
    3D solid model, slice into layers.

    2) Easily manipulated build material (powder)


    to be distributed layer by layer.
    3) Precision scanning to fix the build material at each
    layer.

    Evren YASA
    Ph.D. Candidate
    Dept. of Mechanical Engineering
    K.U.Leuven, Netherlands

    Scanned Laser Fusing and Sintering (SLFS)


    General Operating Principle
    Laser
    Galvanometer-Scanner
    with f-Theta lens
    z
    Recoating
    system

    y
    x

    part

    Building
    platform

    Powder
    reservoir

    Dispenser
    platform

    Turbomeca,
    PEP

    EOS Direct Metal Example parts

    Prototype helicopter stator ring


    in DirectSteel 20

    Ron Arad Associates

    72 turbine wheels DSH20 / 20m


    layers. Build time 28h 15 min
    Blade thickness appr. 0.5mm

    Goldas

    225 parts DM20 / 20m layers in 96 hours


    (ave <30 minutes per part).

    EBM parts

    Prometal (Bathsheeba Grossman)

    V Near Net Shape/Bulk PM Processes

    Near Net Shape Processing:

    Product close to final shape or bulk (ingot)


    Eliminate many manufacturing operations
    Produce preforms, blanks, billet, rod, sheet
    Low productivity vs. die compaction or MIM
    Difficult to process materials and powders
    Continuous processing, large size scale

    V Near Net Shape/Bulk PM Processes

    Isostatic Pressing (hot,cold)


    CIP (Cold Isostatic Pressing):
    Room Temperature
    Up to 60,000 psi
    Flexible rubber tooling
    Generally low tolerances
    Requires post sintering
    90+% density
    HIP (Hot Isostatic Pressing)
    Up to 2000 C
    Metal cans
    Bulk shape (poor tolerances)
    High densities (96-100%)

    V Near Net Shape/Bulk PM Processes

    CIP:
    Cold Isostatic Pressing
    Simple or complex
    shapes
    Low tolerances
    Precursor to other
    processes:
    Extrusion, Swaging,
    Forging, Rolling, etc.

    Examples of HIPd parts

    V Near Net Shape/Bulk PM Processes

    Hot Pressing
    Similar

    to Die Compaction but with


    simultaneous heating/sintering

    Use any form of powder


    Relies on plastic deformation at high temperature
    Rigid tooling: graphite, ceramics, steel, TZM
    Pressures up to 2.5 ton/square inch (graphite tooling)
    Very low production rate vs. Die Compaction
    High density (>98%)
    Composites, layered/gradient materials

    Laboratory
    Hot Press

    Mokume Gane

    Before
    After
    Engineer

    After
    Artist

    Powder Rolling

    Powder Extrusion

    Simultaneous
    consolidation and
    bonding
    Rod, billet
    Can or bare

    Thermal Spray

    Spray Forming

    PM is so easy even a child can understand it.

    Questions?

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