53005236 powder metallurgy seminar gautam copy
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Powder Metallurgy- An insightBy
GAUTAM SHARMA1DA07ME023
DEPARTMRNT OF MECHANICAL ENGG.
DR.AMBEDKAR INSTITUTE OF TECHNOLOGY
BANGALORE-56
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Powder Metallurgy (P/M )Introduction
History
General Summary of the Science of P/M
1.powder production2.powder compaction
3.sintering/ infiltration
Powder metallurgy products
Applications and market
FeasibilityConclusions
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IntroductionPowder metallurgy is the manufacturing process used to
fabricate finished products by the method of compaction of
metal powders and further processing to achieve reqd.
properties.
Current feasible examples of its use are:
Connecting rods of bugatti and jaguars
Use in Automotive industry
Nacelle frame of F-22 raptor Precision equipments and biomedical industry
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HistoryEarly 3000 B.C. a crude form of powdermetallurgy in Egypt
Early 20th Centurycopper coins andmedallions, and tungsten wires
1920s tungsten carbide cutting-tool tips,self-lubricating bearings
1960s full-density products emerged.1970s high-performance superalloycomponents: aircraft turbine engine parts.
1980s the commercialization of rapidlysolidified and amorphous powders and thedevelopment of P/M injection moldingtechnology
After 2000- growing dependence ofautomotive and precision industry.
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G eneral S ummary of The S cience of P/MSTEPS:
a) Powder Production
b) Powder Consolidation
c) Sintering d) Finishing operations
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Powder ProductionAtomizat ion
o Electrolytic, precipitationo Mechanical
o Chemical, reduction
Powder Production
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Powder Production
Disintegration of liquid stream by a second fluid
Gas Atomization
Spherical powder particles
Good "flowability"
Water Atomization:
Irregular powder particles
Good compactability
Powder Production by Atomization
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Atomization SchematicsWater Atomization Induction Coil Gas Atomization
Water Water
Powder Production
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Powder Production Vertical G as Atomizer
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Powder shapes and sizes Chemical: Sponge Iron-
Reduced Ore
Electolytic: Copper
Mechanical: Milled
Aluminum Powder Water Atomization : Iron
Gas Atomization: Nickel-Base Hardfacing Alloy
Powder Production
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Gas Atomized
Silver Alloy
Powder Production
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WaterAtomized
Copper Alloy
Powder Production
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Impart shape to net or near net to powder mass
Net Shape:
Die Compaction
MIM (Metal Injection Molding)
Near Net Shape:
CIP (Cold Isostatic Pressing)
Hot Pressing
Extrusion
Rolling
Powder Consolidation
Consolidation
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Powder Consolidation
Use water atomized powder (irregular shape)
Rigid tooling: tool steel, WC/Co
Pressures up to 60 tons/square inch Production > 10,000 parts
High tolerance, 0.001 "/" possible
High productivity
Controlled porosity, density (85% to 90%)
D ie Compaction
P d C lid i
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Axis-symmetric
No undercuts
No off-axis attributesL/D
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M IM (Metal Injection M olding) Plastic Injection Molding + Powder Metallurgy (P/M)
Complex Shapes
High density metal parts (> 95%)
Economy of Scale (high productivity)
Good tolerance, .003 "/" possible, .005-.008 "/" typ.
Competes wi th inv estment cast ing
and discrete machining
Powder Consolidation
P d C lid ti
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S chematic O f MIMPowder Consolidation
Sintering
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SinteringHeat treatment to promote
Metallurgical integrity
Metallurgical Bonding
Densification (shrinkage)
Pore Elimination
Sintering
Sintering furnace
Sintering
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Sintering
infilt tion
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Infiltration
Infiltration is the process wherein a slug of low melting pointmetal is placed against the sintered parts and then theassembly is heated to a temperature sufficient to melt the slug.The slug infiltrates the pores, to produce a pore free parthaving good density and strength.
Advantages of infiltration are that high strength and density isachieved and pores are filled up, reducing corrosion. Somebearing materials are formed in this way.
infiltration
Products
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Powder M etallurgy Products Porous or permeable products
Oil-impregnated bearings Products of complex shapes that would require considerable machining
when made by other processes
complex shapes such as pawls, cams, and small activating levers
Products made from materials that are difficult to machine or with highmelting points
tungsten lamp filaments and tungsten carbide cutting tools Products where the combined properties of two or more metals are
desired
bearings made of graphite combined with iron or copper
Electrical contacts often combine copper or silver with tungsten, nickelor molybdenum
Products here the powder metallurgy process produces clearly superiorproperties
In areas of critical importance such as aerospace applications
Products
Applications
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P/M . A pplications and M arkets Automotive applications
Aerospace applications
Advanced composites
Magnetic materials Metalworking tools
A variety of biomedical
and dental applications
Applications
Applications
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Porous MetalsOil-impregnated Porous Bronze Bearings
Metal filters
Applications
Applications
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Automotive Industry
Automotive gears
Journal bearings
Connecting rods
Applications
Applications
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C E RM E T cutting tools(Ceramic-Metal composite)Microstructure: ceramic particles in metal matrix
Cermet-tipped saw blade for long
Cermet cutting inserts for lathe
Applications
Applications
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B iomedical and O thers:
KNEE CAPS WITHLUBRICATION
HIGH DENSITY GOLFSTICKS
OTHER HIGH PRECISION
AND SURGICALEQUIPMENTS
Applications
Applications
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Better material utilization
Fewer tool sets
Reduction of secondary machiningoperations
Large end bearing bore and mating flats Eliminate balancing
Cost saving in case of large productionvolume
P/M Press-S inter-Forgevs. Power Forge
Applications
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Feasibility of P/M ProductsCasting, Forging, Machining, P/M, etc:
Which method to choose?
Quality, Quantity, Tolerance,
Geometry, Material, Environment,
Labor quantity, Skill level, Equipment,
Etc
But MOST IMPORTANTLY..
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LOWEST
COST!
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Potential cost savingPart ( in production of F-
22 raptor)Weight( kg) Cost
saving
(%)Forged P/M Final part
Fuselage brace 2.8 1.1 0.8 50
Engine mount support 7.7 2.5 0.5 20
Arrestor hook support 79.4 25.0 12.9 25
Nacelle frame 143 82 24.2 50
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ConclusionsAdvantages:
Elimination or reduction ofmachining
High Production Rates
Complex Shapes can be
Produced Wide Variations in
Compositions are Possible
Wide Variation in
Properties are Available
Scrap is Eliminated or
Reduced
Disadvantages:
Inferior Strength Properties
Relatively High Die Cost
High Material Cost
Design Limitations
Density Variations ProduceProperty Variations
Health and Safety Hazards