Presentation

on

Powder Methods

VIJAY
2008AMD2925

Introduction

Manufacturing process in which fine powder of

materials are Blended or mixed,
Compacted (pressed) in to required shape, size and

surface finish
Sintered (heated)
Controlled atmosphere to bond the contacting
surfaces of particles and
to achieve required
properties like strength, density etc.

High quality, complex parts to close tolerances

in
an
economical
manner
(eliminating
additional machining or finishing operations ).
Controlled degree of density, porosity, strength
and other properties of material, with
minimum waste

Applications
Application
Abrasive
Aerospace
Automotive
Electronic
Joining
Magnetic
Manufacturing
Nuclear

Metals
Fe, Sn, Zn
Al, Be, Nb
Cu, Fe, W
Ag, Au, Mo
Cu, Fe, Sn
Co, Fe, Zn
Cu, Mn, W
Be, Ni, W

Uses
Cleaning, abrasive wheels
Jet engine, heat shield
Valve insert, bushing, gears
Diode heat sink
Solder, electrode
Relay, magnets
Dies, tools, bearings
Shielding, filters, reflector

Table1:Application
of powder
Tungsten lamp
filaments,
oil-less
bearings, automotive
methods [1]
transmission
gears, electrical contacts, nuclear power fuel elements, aircraft
brake
pads, jet engine components, printed circuit boards, explosives,
welding electrodes, rocket fuels, etc [2]

Production of a
component
1.
2.
3.
4.
5.

Production of powder
Preparation of powder including blending and
mixing
Compacting
Sintering
Post sintering treatment [3]

Production of Powder
1. Mechanical method (milling)
Ball mills and roller mills
Ferrous and non ferrous materials
Brittle

Fig 1:- Ball mill

Image courtesy: - R

Production of Powder

2. Electrolytic Deposition

Spongy or powdery state of metal

Suitable conditions; composition and strength of the

electrolyte, temperature, current density, etc

Copper, chromium and manganese powders
Pure powder

Fig 2:- Electrolytic

deposition

Image courtesy: Ref. [2]

Production of Powder
3. Reduction of ores

Iron powder

4. Atomisation
Liquid metals Orifice- Jet stream of gas, water, or
steam Broken into fine particles
To control particle size distribution

Parameters; design and configurations of the jets, pressure

and volume of the atomising fluid, thickness of the stream

of metal, etc

Production of iron, tool steels, alloy steels, copper, brass,

bronze and the low-melting-point metals, such as
aluminium, tin, lead, zinc, cadmium powders. [2]

Fig 3:- Vertical gas atomization unit

Image courtesy: Ref. [5]

Preparation of powder
Blending and Mixing
To obtain desired properties and characteristics we
have to mix

Powder of different materials -different grades and

sizes- different composition

Lubricants and binders.
Alloying elements

Fig 4:- Powder

contents- Ref. [2]
Image Courtesy:

Compacting
Loose powder of material is compressed and densified Green

compact- At room temp.

Mechanical, hydraulic and pneumatic presses .

Fig 5:- Compaction sequence

(1)Cycle start
(2)Charge die with powder
(3)Compaction begin
(4) Compaction completed
(5) Ejection of part
(6) Recharging die

Image Courtesy: - Ref.[2]

Sintering
Green compact is heated in a controlled atmosphere
Below the melting point but high enough to permit solid

state diffusion
Held for sufficient time to permit bonding of the particles
Sintering temperature range for iron-based alloys is
1100-1150C and the time varies between 10 and 60
minutes, depending on the application [6]

Fig 6:- Sintering process

Image Courtesy: Ref. [7]

Post sintering treatments

Machining
De-burring
Joining
Heat treatment
Double Pressing
Oil Impregnation

Advantages of the powder

methods

Complex shapes can be produced.

Close dimensional accuracy with elimination
or reduction in machining.
High production rate due to automation.
Wide range of properties like density, porosity
and particle size can be obtained.
No waste during fabrication.
Highly skilled labour is not required. [8]

Disadvantages and
Pure metal powders are very expensive.
limitations

Size of part produced is limited.

Alloy powders are not easily obtained.
Strength properties are lower than product
manufactured by convention way.
Increased tendency to oxidation due t pores.
Poor plastic properties like impact strength,
elongation etc.
High pressure and severe abrasion involved in
process increase the die cost. [8]

References:1.

2.
3.
4.
5.
6.
7.
8.

Manufacturing Engineering and Technology by

Seropr
Kalpakjian and Steven R. Schmid ,
Chapter 17, Table 17.1 Page 461
http://www.turktoz.gazi.edu.tr
Manufacturing Engineering Processes by Leo
Alting, Chapter 9, Page 281-299
http://www.ktf-split.hr/glossary/image/ball_mill.gif
http://www.xstreamscience.org/H_Glaze/assets/Po
wder%20Atomizer.gif
http://www.substech.com
http://www.azom.com/details.asp?ArticleID=132
Elements of Workshop Technology by S.K. and
A.K. Hajra Choudhury, Chapter 12, Page 431-440.

Thank You.