1.

0 Introduction
The powder metallurgy (P/M) process, in which metal powders are
compacted into desired and often complex shapes and sintered (heated
without melting) to form a solid piece.
Powder metallurgy has become competitive with processes (such as casting,
forging, and machining), particularly for relatively complex parts made of
high strength and hard alloys.
The most commonly used metals in P/M are iron, copper, aluminum, tin,
nickel, titanium, and the refractory metals.
The powder-metallurgy process consists of the following operations, in
sequence:
Powder production

Blending
Compaction
Sintering
Finishing operations

Fig 1 (a) shows the examples of typical parts made by powder-metallurgy processes. (b)
Upper trip lever for a commercial irrigation sprinkler made by P/M. This part is made of
an unleaded brass alloy; it replaces a die-cast part with a 60% cost savings. (c) Mainbearing metal-powder caps for 3.8 and 3.1 liter General Motors automotive engines.

Why Powder Metallurgy is Important ?

PM parts can be mass produced to net shape or near net
shape, eliminating or reducing the need for subsequent
machining
PM process wastes very little material - ~ 97% of starting
powders are converted to product
PM parts can be made with a specified level of porosity, to
produce porous metal parts
Examples: filters, oil-impregnated bearings and gears

 Certain metals that are difficult to fabricate by other

methods can be shaped by powder metallurgy

Tungsten filaments for incandescent lamp bulbs are

made by PM
Certain alloy combinations and cermets made by PM
cannot be produced in other ways

PM compares favorably to most casting processes in

dimensional control
PM production methods can be automated for economical
production

Advantages of PM
Although the cost of metal powder is high, there is no loss of material. The
parts can be produced clean & bright, ready for use.- Net shape and near
shape products.
Composition of product can be controlled. No risk of contamination.
Close dimensional tolerances can be maintained.
Non-metallic substances can be produced and in any proportion to get the
final product.
A wide range of properties such as density, porosity and particle size can
be obtained for particular applications.
It is possible to unite materials that cannot be alloyed in the normal sense or
would not yield the desired characteristics.
Useful for magnetic core having special desirable properties.
Reduction in the production time.
No skill labor is required.
Saving material and 97 % is possible.
Composition, structure and properties can be controlled more easily and closely
than any other fabricating process.

Limitations and disadvantages

Pure metal powders are very expensive to produce.
Size of the products to be produced is limited because of the large presses
are required.
Lack of metals powder like steels, bronzes, brasses etc.
Strength properties are lower than those of similar article produced by
conventional methods.
Poor plastic properties impact strength and elongation.
Die design limit the size of products.
Dies required are very expensive and needed large quantities of products.
Volume must be justified.

Fig 2 Outline of processes and operations involved in producing powder

metallurgy parts.

2.0 Powder Production

The choice depends on the requirements of the end product.

The microstructure, bulk and surface properties, chemical purity,

porosity, shape, and size distribution of the particles depend on the
particular process used.

Fig 3 shows the particle shapes in metal powders, and the processes by
which they are produced. iron powders are produced by many of these
processes.
What are the principal methods used to produce metallic powders?
Answer. The powder production methods are (1) atomization - the conversion of molten
metal into
droplets which solidify into powders; (2) chemical reduction - reducing metallic oxides by
use of
reducing agents which combine with the oxygen to free the metals in the form of powders;
and (3)
electrolysis - use of an electrolytic cell to deposit particles of the metal onto the cathode in
the cell.

FIGURE 3 Particle shapes in metal powders, and the processes by which they
are produced; iron powders are produced by many of these processes (see also
Fig. 17.4).

FIGURE 4 (a) Scanning-electron microscope image of iron-powder particles

made by atomization. (b) Nickel-based superalloy (Udimet 700) powder
particles made by the rotating electrode process;.
Source: Courtesy of P.G. Nash, Illinois Institute of Technology, Chicago.

2.1 Method of Metal Powder

2.1.1 Atomization

Atomization produces a liquid-metal stream by injecting molten metal

through a small orifice.

Fig 5 show the methods of metal-powder production by atomization: (a)

gas atomization; (b) water atomization; (c) atomization with a rotating
consumable electrode; and (d) centrifugal atomization with a spinning
disk or cup.

In centrifugal atomization, the molten-metal stream drops onto a rapidly

rotating disk or cup, so that centrifugal forces break up the molten-metal
stream and generate particles.

FIGURE 5 Methods of metal powder production by atomization: (a) gas atomization; (b)
water atomization; (c) centrifugal atomization with a spinning disk or cup; and (d)
atomization with a rotating consumable electrode.