PM Powder Metallurgy

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P/M (Powder Metallurgy)

• Joseph Tunick Strauss
• HJE Company, Inc.
• Glens Falls, South Glens Falls, and Queensbury,
  NY

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Powder Metallurgy (P/M)
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Powder Metallurgy (P/M)
I Introduction II General Summary of
the Science of P/M III P/M
Manufacturing Techniques IV Applications,
General Case Studies
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P/M The use of metal (or ceramic) powders in
industrial applications

• Consolidation into dense parts shapes
• Structural / machine parts
• Cutting tools
• Oil impregnated bushings, filters
• Fusion / Welding
• Solder and brazing pastes
• Welding and thermal spray
• Other
• Chemical
• Agricultural
• Food and pharmaceuticals

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I Introduction
Casting, Forging, Machining, P/M, etc Which
method to choose? Quality, Quantity, Tolerance,
Geometry, Material, Environment, Labor quantity,
Skill level, Equipment, Etc
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I Introduction
LOWEST COST!
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I Introduction (cont.)

• POWDER METALLURGY (P/M)
• Full-scale Industrialization in past 50 years
• gt1.8 Billion per year in North America
• P/M Processing has Shown Continuous Annual Growth
  for the Past 50 Years by
• 1) Replacing Existing Technologies
• 2) "DFM Designed for Manufacturability"
• Keep in mind that powder cost more than
  equivalent
• cast or wrought material

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II General Summary of The Science of P/M

• P/M consists of three fundamental steps
• a) Powder Production
• b) Powder Consolidation
• c) Sintering

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II General Summary of The Science of P/M

• a) Powder Production
• Atomization
• Electrolytic, precipitation
• Mechanical
• Chemical, reduction

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II General Summary of The Science of P/M

• a) Powder production by Atomization
• Disintegration of liquid stream by a second
  fluid
• Gas Atomization
• Spherical powder particles
• Good "flowability"
• Water Atomization
• Irregular powder particles
• Good compactability

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Atomization Schematics
Water Atomization Induction Coil
Gas Atomization
Water
Water
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Gas Atomized Silver Alloy
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Water Atomized Copper Alloy
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II General Summary of The Science of P/M

• b) Consolidation
• 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

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II General Summary of The Science of P/M

• c) Sintering
• Heat treatment to promote metallurgical
  integrity
• Metallurgical Bonding
• Densification (shrinkage)
• Pore Elimination

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III P/M Manufacturing Techniques

• Net Shape Processing
• Direct process to final shape
• Eliminate manufacturing operations
• "Chipless" manufacturing,
• low waste/scrap

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III P/M Manufacturing Techniques Net Shape
Processing

• Die Compaction
• Use water atomized powder (irregular shape)
• Rigid tooling tool steel, WC/Co
• Pressures up to 60 tons/square inch
• Production gt 10,000 parts
• High tolerance, 0.001 "/" possible
• High productivity
• Controlled porosity, density (85 to 90)

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• Axis-symmetric
• No undercuts
• No off-axis attributes
• L/D lt5

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III P/M Manufacturing Techniques Net Shape
Processing

• MIM (Metal Injection Molding)
• Plastic Injection Molding Powder Metallurgy
  (P/M)
• Complex Shapes
• High density metal parts (gt 95)
• Economy of Scale (high productivity)
• Good tolerance, .003 "/" possible, .005-.008 "/"
  typ.
• Competes with investment casting
• and discrete machining

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IV Applications, General Case Studies
Connecting Rod
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IV Applications, General Case Studies
Connecting Rod

• P/M Press-Sinter-Forge
• vs. Power Forge
• Better material utilization
• Fewer tool sets
• Reduction of secondary machining operations
• Large end bearing bore and mating flats
• Eliminate balancing

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IV Applications, General Case Studies
Orthodontia Brackets

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IV Applications, General Case Studies
Orthodontia Brackets

• MIM vs. Discrete machining and Investment
  casting
• Elimination of all machining operations
• Better material utilization (no chips, sprues,
  etc)
• Able to produce smaller parts than investment
  cast
• Able to produce more complex geometries than
  machining
• Massive reduction in labor
• Complete payback in about 2 years

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IV Applications, General Case Studies
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IV Applications, General Case Studies
Wedding Band Blanks
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IV Applications, General Case Studies
Wedding Band Blanks

• P/M rings vs. Conventional methods
• (stamp from sheet, cut from
  tube )
• Far Better material utilization (sheet scrap,
  saw kerf waste)
• Lower cost material (wrt added value)
• Massive reduction in labor
• Improved material properties, better
  machinability

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Applications, General Case Studies Jewelry
Applications

• MIM Applications for Jewelry Items
• Reduction in Labor
• Reduction in Defect Rate
• Reduction in Precious Metal Content

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Soluble Core MIM
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Sinter-bonded MIM for hollow jewelry
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P/M is so easy even a child can understand it.