University of Michigan-Dearborn

WINTER 2018

ME 593, Powder Materials and Processing

Assignment 3
(03/21/2018)

Due date: 04/02/2018 (in class)

Total Points: 25

1. Iron powder (theoretical density 7.86 g/cm3) is lubricated with 1 wt.% zinc stearate powder
(theoretical density 1.09 g/cm3) in a double-cone mixer. Calculate the theoretical density
of the mixture. Assume uniform mixing. [Points: 5]

2. The green density for a stainless steel powder compact is targeted at 6.5 g/cm 3. The
apparent density of the powder is 2.7 g/cm3. What is the compression ratio? [Points: 3]

3. What merit would be there forming steel compacts by pressing mixed iron (Fe) and
graphite (C) powders rather than using pre-alloyed powders? [Points: 4]

4. An irregular copper (Cu) powder (-200 mesh) is compacted and measured for green
properties. The results of the study are shown below. [Points: 8]

Pressure Fractional density Strength

(MPa) (%) (MPa)

0 12.2 -

25 24.7 -

70 45 4.3

120 59.3 9.3

210 71.3 18.4

335 79.1 27.1

510 85.6 35.6

650 86.9 36.7

770 88.3 38.3

880 88.8 38.9

990 88.9 39.1

[A] Select a model for green density dependence on the compaction pressure and perform
a graphical fit to the data. Explain the observed fractional density dependence on the
compaction pressure and suggest probable mechanisms.
 [B] What is the approximate apparent density of the Cu powder?

[C] For handling of compacts made out of these powders, in subsequent operations, if the
green strength requirement is 38.5 MPa, then estimate the green density of the compact.

[D] Estimate the porosity of the compact (corresponding to the above green density).
Suggest at least one way to reduce the porosity.

Assume the true density of copper ~8.9 g/cm3

5. Compact density below a pressure drop of 50% is considered unacceptable for hard
powder such as 5 μm molybdenum (Mo). The friction coefficient (μ) with the die wall is
~0.3 while the radial to axial pressure ratio (k) is 0.5. Estimate the maximum allowable
height of a compact (1 cm diameter) in (a) single action pressing/compaction and (b)
double-action pressing/compaction. [Points: 5]