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Fig. 1 Diffusion bonding process: (a) apply metal foil and cut to shape, (b) lay up desired
plies, (c) vacuum encapsulate and heat to fabrication temperature, (d) apply pressure and
hold for consolidation cycle, and (e) cool, remove, and clean part
The best known examples of MMCs produced by diffusion bonding are titanium,
nickel, copper and particularly aluminium reinforced with boron fibers.
The principal advantages of this technique are the ability to process a wide variety
of metal matrices and control of fiber orientation and volume fraction.
Among the disadvantages are long processing times, high processing temperatures
and pressures (which makes the process expensive), and a limitation on the complexity of
shapes that can be produced.
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POWDER METTALLURGY
It is a manufacturing process in which components are directly made by bringing a
powder of starting material into final desired shape by compressing the powder in dies, can
produce as well as high density parts.
Powder metallurgy is especially suited for the production of discontinuous fiber, whiskers
or particulate reinforced metals.
The powder metallurgy process has been used to produce composites such as boron,
carbon and borsic fibers with aluminium alloy, SiC fibers with chromium alloys, boron and
Al2O3 fibers with titanium alloy, tungsten and molybdenum fibers with nickel alloy and several
other composite systems. Powder metallurgy is a versatile process but its application to
fabrication of metal matrix composites may not be straight-forward, especially because of the
presence of reinforcement phase. Major areas of application tend to be those for which the P/M
process has strong economical advantage or where the desired properties and characteristics
would be difficult to obtain by any other method.
MANUFACTURING STEPS
1. Powder preparation
Atomization
Machining
Reduction
Crushing and milling
Electro decomposition
Shotting
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Elemental or alloy
metal powders
Additives
(lubricants or
Blending
Die Compacting
Sintering
Optional
Secondary
Manufacturing
Optional
Secondary
Finishing
Finished P/M product
POWDER PREPARATION
ATOMISATION
Molten metal is broken into small droplets by spraying it on incoming compressed air,
water jets or inert gas. Air and water jet induces oxidation of powder. Control of metal flow rate,
pressure and temperature of air or water controls the powder size used for low melting point
alloys like brass, bronze, zinc, tin, lead and aluminium.
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Representative Metal Powders: (a) Chemical; Sponge Iron-Reduced Ore; (b) Electolytic:
Copper; (c) Mechanical: Milled Aluminum Powder Containing Disperoids (17); (d) Water
Atomization : Iron; (e) Gas Atomization: Nickel-Base Hardfacing Alloy
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MACHINING
The materials are machined to fine coarse powder. Magnesium is produced by this
process.
REDUCTION
Metal oxide is treated with a suitable reducing gas an elevated temperature below its
melting point. The pure metal so obtained is crushed and milled to a powder. Process is cheap
and large quantity of powder can be produced. Particles are of irregular size. W, Mo, Ni and Co
are made by Hydrogen reduction.
CRUSHING AND MILLING
Used for brittle metals and utilize various types of crushes, rotary mills and stamping
mills to break down the metals by impact. Gyrator, cone or roller crushers obtain first coarse
material powder. Filter powder is got by ball miller hammer mill.
ELECTRO DEPSITION
To make iron powder impure steel plates act as anodes and sheets of stainless steel act as
cathodes placed in an electrolyte. When Direct current is passed spongy iron gets deposited on
cathode plates. This is shopped off and crushed. Copper, silver and tantalum powders are made
by this process.
SHOTTING
This method consists of pouring a fine stream of molten metal through a vibrating screen
into air or natural atmosphere. In this way molten metal is disintegrated into a large number of
droplets, which solidify as solid spherical particles. Copper, brass, aluminium, zinc, gold, silks,
led, nickel, etc are examples
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Methods
Pressure less shaping
In this the required shape is given by to a powder mass prior to sintering it without
applying an external pressure.
E.g.: slip casting, slurry
Cold pressure shaping
In this process have largest scope for shaping metal powders. Cold die compaction,
isostatic pressing, explosive forming, high energy rate forming, powder rolling cyclic
compacting, centrifugal compaction, powder extrusion.
Pressure shaping technique with heat
It include hot isostatic pressing, hot working, spark sintering etc.
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SINTERING
The green compact so obtained will be rather very fragile due to limited degree inter
particle bonding.
Sintering is a process of heating a loosely compacted aggregate of metal powders below
the melting point of the vase metal with or without the application of external pressure in order
to perform it to a more dense material by inter particle bonding.
Sintering is a concerned with diffusion of particle to particle the formation of grain
boundary, closing the voids present in the green briquettes.
ADVANTAGES OF POWDER METALLURGY OVER OTHER CONVENTIONAL
MELTING AND CASTING METHODS
1.
2.
3.
4.
5.
casting
6. Control of grain size, relatively much uniform structure
7. Excellent reproducibility
8. Improved physical and structural properties
9. Ability to offer complex shape
10. Elimination of numerous machining operations
11. Possibility of producing new materials by mixing different materials and obtain
improved properties.
LIMITATIONS
1. Difficult to get extremely pure powders. Powder production is expensive
2. Inferior Strength Properties
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3.
4.
5.
6.
Aerospace application
Recreational equipment
Hand tools
Hardware items
Business machines
Industrial motors
Hydraulics
Home appliances
Aerospace applications
Advanced composites
Electronic components
Magnetic materials
Metalworking tools
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