Parul Institute of

Engg & Tech

POWDER METALLURGY

Department : Mechanical Engineering

Student
Name

Enrollment
No

Milan Panchal

140370119194

Harshal Parikh

140370119198

Kunal Patel

140370119206

Abhishek Patel

140370119208

K.B. Lamba

Definition
science of producing metal powders
and making finished
/semifinishedobjects from mixed or
alloyed powders with or without the
addition of nonmetallic constituents
Particulate technology is probably the
oldest forming technique known to
man.
First Modern product was the
tungsten filament for the light bulb in
1910.

Process of Powder
Metallurgy

The process of P/M in general consists of a

series of steps/stages to form a final shape.
These stages are shown by a simple flow sheet
Powder Production
diagram.
Powder Characterization & testing

Mixing - Blending
Processing - Compacting
Sintering Operation

Finishing Operations
Finished P/M Parts

Animation of POWDER
METALLURGY

General steps in the

P/M process

Powder Metallurgy
Component Production
Cycle

Powder Metallurgy
Processing
Powder fabrication
POWDER

Size and shape

characterization
Microstructure (e.g.. dendrite
size)
Compaction
Chemical
homogeneity, and

PROCESSING

ppt.
size
Sintering
Forging/Hot
pressing
Density, Porosity
Ductility, Strength

PROPERTIES

Conductivity
Other functional properties

Characteristics of metal
powders:
The performance
of metal powders during
processing and the properties of the product are
highly dependent on the characteristics of the
metal powders that are used.
The most important characteristics of metal
powders are :
1.Purity
2.Chemical composition
3.Particle size
4.Particle shape
5.Size distribution
6.Particle microstructure

1. Powder Production
Many methods: extraction from
compounds,
deposition,
atomization, fiber production,
mechanical powder production, etc.
Atomization is the dominant process

(a)

(b)

(c)

(a) Water or gas atomization; (b) Centrifugal atomization; (c) Rotating elec

Characterization of
Powders

Size of powders 0.1 um 1 mm

Sieve size quoted as mesh
number
Particle D = 15/mesh number
(mm)

2. Blending or Mixing
Blending a coarser fraction with a finer
fraction ensures that the interstices
between large particles will be filled
out.
Powders of different metals and other
materials may be mixed in order to
impart
special physical and mechanical
properties through metallic alloying.
Lubricants may be mixed to improve the
powders flow characteristics.
Binders such as wax or thermoplastic
polymers are added to improve green
strength.

Blending and mixing are

accomplished by mechanical
means:

3.Compacting
Press powder into the desired shape and size in dies
using a hydraulic or mechanical press
Pressed powder is known as green compact The

green strength of the part when pressed is

adequate for handling.

4. Powder
Consolidation
Cold compaction with 100

900 MPa to produce a

Green body.
Die pressing
Cold isostatic pressing
Rolling
Gravity
Injection Molding small,
complex parts.

Die pressing

5. Sintering
Transforms compacted mechanical bonds to much
stronger metallic bonds.

Heat treatment to bond the metallic particles,

therebyincreasing strength and hardness.
Usually carried out at between 70% and 90% of
the metal's melting point (absolute scale).

Generally agreed among researchers that the

primary driving force for sintering is reduction of
surface energy.

5. Finishing
The porosity of a fully sintered part
is still significant (4-15%).
Density is often kept intentionally
low to preserve interconnected
porosity for bearings, filters,
acoustic barriers, and battery
electrodes.
However, to improve properties,
finishing processes are needed:
Cold restriking, resintering, and
heat treatment.
Impregnation of heated oil.

Special Process: Hot

compaction
Advantages can be gained by combining

consolidation and sintering,

High pressure is applied at the sintering
temperature to bring the particles together
and thus accelerate sintering.
Methods include
Hot pressing
Spark sintering
Hot isostatic pressing (HIP)
Hot rolling and extrusion
Hot forging of powder preform
Spray deposition

Finished Powder Metallurgy

Powder Metallurgy
Merits
Near Nett Shape is possible, thereby reducing
the post-production costs, therefore:

Precision parts can be produced

The production can be fully automated, therefore,

Mass production is possible

Production rate is high

Over-head costs are low

Break even point is not too large

Material loss is small

Advantages and
Disadvantages of P/M

Virtually unlimited choice of alloys,

composites, and associated properties.
Refractory materials are popular by this
process.
Controlled porosity for self lubrication or
filtration uses.
Can be very economical at large run sizes
(100,000 parts).
Long term reliability through close control of
dimensions and physical properties.
Very good material utilization.
Limited part size and complexity
High cost of powder material.
High cost of tooling.