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By S K Mondal
Powder Metallurgy
Powder metallurgy is the name given to the
process by which fine powdered materials are
blended, pressed into a desired shape
(compacted), and then heated (sintered) in a
controlled atmosphere to bond the contacting
surfaces of the particles and establish the desired
properties.
Manufacturing of Powder
Atomization using a gas stream
Molten metal is
forced through a
small orifice and
is disintegrated by
a jet of
compressed air,
inert gas or water
jet,. It is used for
low melting point
materials, brass,
bronze, Zn, Tn,
Al, Pb etc.
Manufacturing of Powder
Reduction
Metal oxides are turned to pure metal powder when
exposed to below melting point gases results in a
product of cake of sponge metal.
The irregular sponge-like particles are soft, readily
compressible, and give compacts of good pre-sinter
(“green”) strength
Used for iron, Cu, tungsten, molybdenum, Ni and
Cobalt.
Manufacturing of Powder
Electrolytic Deposition
Used for iron, copper, silver
Process is similar to electroplating.
For making copper powder, copper plates are placed as
anode in the tank of electrolyte, whereas the aluminium
plates are placed in the electrolyte to act as cathode.
When DC current is passed, the copper gets deposited
on cathode. The cathode plated are taken out and
powder is scrapped off. The powder is washed, dried and
pulverized to the desired grain size.
The cost of manufacturing is high.
Manufacturing of Powder
Granulations - as metals are cooled they are stirred rapidly
Machining - coarse powders such as magnesium
Milling - crushers and rollers to break down metals. Used for
brittle materials.
Shooting - drops of molten metal are dropped in water, used
for low melting point materials.
Condensation – Metals are boiled to produce metal vapours
and then condensed to obtain metal powders. Used for Zn,
Mg, Cd.
GATE -2011 (PI)
Which of the following powder production
methods produces spongy and porous particles?
(a) Atomization
(b) Reduction of metal oxides
(c) Electrolytic deposition
(d) Pulverization
IES - 2012
In electrolysis
(a) For making copper powder, copper plate is made
cathode in electrolyte tank
(b) For making aluminum powder, aluminum plate is
made anode
(c) High amperage produces powdery deposit of cathode
metal on anode
(d) Atomization process is more suitable for low melting
point metals
Characteristics of metal powder:
Fineness: refers to particle size of powder, can be
determined either by pouring the powder through a sieve or
by microscopic testing. A standard sieves with mesh size
varies between (100) and (325) are used to determine
particle size and particle size distribution of powder in a
certain range.
Particle size distribution: refers to amount of each particle
size in the powder and have a great effect in determining
flowability, apparent density and final porosity of product.
Blending
Blending or mixing operations can be done either dry or wet.
product complexity)
No lubricant is needed
No molten metals
(a) Casting
(b) welding
(c) formation
(a) P – 4, Q – 3, R – 2, S – 1 (b) P – 2, Q – 4, R – 3, S - 1
(c) P – 2, Q – 1, R – 4, S – 3 (d) P – 4, Q – 1, R – 2, S - 3
Conventional Questions
1. Explain why metal powders are blended. Describe what
happens during sintering. [IES-2010, 2 Marks]
Conventional Questions
1. Discuss the terms fineness and particle size
distribution in powder metallurgy. [IES-2010, 2 Marks]
Ans.
Fineness: Is the diameter of spherical shaped particle
and mean diameter of non-spherical shaped particle.
Particle size distribution: Geometric standard
deviation (a measure for the bredth or width of a
distribution), is the ratio of particle size diameters
taken at 84.1 and 50% of the cumulative undersized
weight plot, respectively and mean mass diameter
define the particle size distribution.
Conventional Questions
Enumerate the steps involved in “powder metallurgy”
process. Discuss these steps. Name the materials used
in “powder metallurgy”. What are the limitations of
powder metallurgy? [IES-2005, 10 Marks]
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Atomization
Produce a liquid-metal
stream by injecting molten
metal through a small
orifice
Stream is broken by jets of
inert gas, air, or water
The size of the particle
formed depends on the
temperature of the metal,
metal flowrate through the
orifice, nozzle size and jet
characteristics
Variation:
A consumable electrode is
rotated rapidly in a helium-
filled chamber. The
centrifugal force breaks up
the molten tip of the
electrode into metal
particles.
Fe powders made by atomization Ni-based superalloy made by
the rotating electrode process
Reduction
Reduce metal oxides with H2/CO
Powders are spongy and porous and they have uniformly
sized spherical or angular shapes
Electrolytic deposition
Metal powder deposits at the cathode from aqueous solution
Powders are among the purest available
Carbonyls
React high purity Fe or Ni with CO to form gaseous carbonyls
Carbonyl decomposes to Fe and Ni
Small, dense, uniformly spherical powders of high purity
Comminution
Crushing
Milling in a ball mill
Powder produced
Brittle: Angular
Ductile: flaky and not particularly suitable for P/M
operations
Mechanical Alloying
Powders of two or more metals are mixed in a ball mill
Under the impact of hard balls, powders fracture and join
together by diffusion
(a) Roll crusher, (b) Ball mill
BLENDING
To make a homogeneous mass with uniform distribution of
particle size and composition
Powders made by different processes have different sizes
and shapes
Mixing powders of different metals/materials
Add lubricants (<5%), such as graphite and stearic acid,
to improve the flow characteristics and compressibility
of mixtures
Combining is generally carried out in
Air or inert gases to avoid oxidation
Liquids for better mixing, elimination of dusts and reduced
explosion hazards
Hazards
Metal powders, because of high surface area to volume ratio are
explosive, particularly Al, Mg, Ti, Zr, Th
Some common equipment geometries used for blending powders
(a) Cylindrical, (b) rotating cube, (c) double cone, (d) twin shell
COMPACTION
Press powder into the desired shape and size in dies using a
hydraulic or mechanical press
Pressed powder is known as “green compact”
Stages of metal powder compaction:
Increased compaction pressure
Provides better packing of particles and leads to ↓
porosity
↑ localized deformation allowing new contacts to be
formed between particles
At higher pressures, the green density approaches density
of the bulk metal
Pressed density greater than 90% of the bulk density is
difficult to obtain
Compaction pressure used depends on desired density
Smaller particles provide greater strength mainly due to
reduction in porosity
Size distribution of particles is very important. For same
size particles minimum porosity of 24% will always be
there
Box filled with tennis balls will always have open space between
balls
Introduction of finer particles will fill voids and result in↑ density
Because of friction between (i) the metal particles and (ii)
between the punches and the die, the density within the
compact may vary considerably
Density variation can be minimized by proper punch and
die design
(a) and (c) Single action press; (b) and (d) Double action press
(e) Pressure contours in compacted copper powder in single action press
Compaction pressure of some metal powders
Al 75-275
Al2O3 100-150
Brass 400-700
Carbon 140-170
Fe 400-800
W 75-150
WC 150-400
(a) Compaction of metal powder to form bushing
(b)Typical tool and die set for compacting spur gear
A 825 ton mechanical press for compacting metal powder
Cold Isostatic Pressing
Metal powder placed in
a flexible rubber mold
Assembly pressurized
hydrostatically by
water (400 – 1000
MPa)
Typical: Automotive
cylinder liners →
FFT: Advantages?
SINTERING
Green compact obtained after compaction is brittle and
low in strength
Green compacts are heated in a controlled-atmosphere
furnace to allow packed metal powders to bond together
Carried out in three stages:
Promotes solid-state
bonding by diffusion.
Diffusion is time-
temperature sensitive.
Needs sufficient time
•Promotes vapour-phase
transport
•Because material
heated very close to
MP, metal atoms will
be released in the
vapour phase from the
particles
•Vapour phase
resolidifies at the
interface
Third stage: Sintered product is cooled in a controlled
atmosphere
Prevents oxidation and thermal shock
Steps in HIP
Simultaneous compaction + sintering
Container: High MP sheet metal
Container subjected to elevated temperature and a very
high vacuum to remove air and moisture from the
powder
Pressurizing medium: Inert gas
Operating conditions
100 MPa at 1100 C
Ch-12: Powder Metallurgy
Q. No Option Q. No Option
1 D 5 C
2 B 6 B
3 C 7 D
4 A 8 C