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					               Powder Metallurgy
       Presented by: Dr. Joseph Strauss – HJE Co.




General Manufacturing Processes Engr.-20.2710
         Instructor - Sam Chiappone
        Powder Metallurgy (PM)
   PM is the use of metal powders in industrial
    applications




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               Rensselaer Polytechnic Institute     Chiappone
                      Applications
   Consolidation into dense parts & shapes
    – Structural / machine parts
    – Cutting tools
    – Filters
   Fusion / Welding
    – Solder and brazing pastes
    – Welding and thermal spray
   Other
    – Chemical
    – Agricultural
    – Food and pharmaceuticals

                                                     GMP-20.271
                  Rensselaer Polytechnic Institute    Chiappone
                     Why PM?
   Cost advantage
   Only option
   Better properties




                                                  GMP-20.271
               Rensselaer Polytechnic Institute    Chiappone
                  Applications
   The vast majority of PM application is the
    consolidation of powder onto dense parts and
    shapes




                                                  GMP-20.271
               Rensselaer Polytechnic Institute    Chiappone
                  Process Steps
   Powder manufacturing
   Powder mixing and or blending
   Powder compacting into shape
   Powder bonding
    – Density
    – Mechanical properties
    – Metallurgical integrity


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                Rensselaer Polytechnic Institute    Chiappone
  Process Steps




                                   GMP-20.271
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                   Powder Sources
   Atomization of liquid metal
    – Gas, water/oil, and mechanical
   Chemical
    – Reduction, reaction, precipitation, and electrolytic
        » Fe2O3 (s) + 3H2 (g)  2Fe (s) +3H2O (g)
        » Fe(CO)5 (g) + catalysis  Fe (s) + 5CO (g)
        » Ni (s) + Al (s)  NiAl (s)
        » 2AgNO3 (aq) + 2K2SO3 (aq)  2Ag (s) + K2SO4 (aq) + 2K2NO3 (aq)
          SO2 (aq)
        » Cu++ + 2e  Cu (s)
   Mechanical: milling and or grinding

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                   Rensselaer Polytechnic Institute              Chiappone
Powder Sources




                                   GMP-20.271
Rensselaer Polytechnic Institute    Chiappone
Powder Sources




                                   GMP-20.271
Rensselaer Polytechnic Institute    Chiappone
Powder Sources




                                   GMP-20.271
Rensselaer Polytechnic Institute    Chiappone
          Powder Characteristics
   Particle size and size distribution
   Particle shape
   Physical properties
    – Hardness and Ductility
   Chemical
    – Composition, reactivity, and impurities
   Bulk properties
    – Flow properties, apparent density, tap density,
      compressibility, and green strength

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                Rensselaer Polytechnic Institute         Chiappone
                   Consolidation
   Consolidation = to impart shape or form
   Net shape methods
    – Pressing, die compaction (hot or cold)
    – Metal injection molding (MIM)
    – Cold isostatic pressing (CIP)
   Bulk shape methods
    –   Hot isostatic pressing (HIP)
    –   Cold isostatic pressing (CIP)
    –   Roll
    –   Extrude
    –   Spray form
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                 Rensselaer Polytechnic Institute    Chiappone
Consolidation – Net Shape




                                       GMP-20.271
    Rensselaer Polytechnic Institute    Chiappone
Consolidation – Net Shape




                                       GMP-20.271
    Rensselaer Polytechnic Institute    Chiappone
Consolidation - MIM




                                     GMP-20.271
  Rensselaer Polytechnic Institute    Chiappone
Consolidation - Bulk




                                     GMP-20.271
  Rensselaer Polytechnic Institute    Chiappone
Consolidation - Bulk




                                     GMP-20.271
  Rensselaer Polytechnic Institute    Chiappone
                       Sintering
   Metallurgical bonding of powder particles
    – Solid state diffusion
    – Liquid phase
   Thermal activated event
    – Atomic transport
    – Particle rearrangement
    – Particle growth
   Results
    – Densification, yield useful physical properties (UTS,
      YS, ductility, and fatigue strength)

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                Rensselaer Polytechnic Institute       Chiappone
       Sintering




                                   GMP-20.271
Rensselaer Polytechnic Institute    Chiappone
       Sintering




                                   GMP-20.271
Rensselaer Polytechnic Institute    Chiappone

				
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posted:9/23/2012
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