Finishing Operations In Manufacturing|Powder Metallurgy Applications

Finishing Operations In Manufacturing

Sizing:

Repressing the sintered component in a die to meet required tolerances.

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02-Sizing-Sintering-Height gauge

Coining:

Repressing the sintered component in a die to increase the density and to give additional strength.

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Infiltration:

Filling the pores of sintered product with molten metal to improve the physical properties.

Impregnation:

Filling of Oil, Grease or other Lubricants in a Sintered components such as Porous Heating

Machining:

Removing excess material by using cutting tool to imparts specific features such as Threads, Grooves, Undercuts etc, which are not practicable in powder metallurgy process.

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Heat Treatment:

Process of Heating & Cooling at a desired rate to improve Grain Structure, Strength & Hardness.

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Corrosion Plating:

Used for obtaining Resistance to Corrosion or better appearance.

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Powder metallurgy is used in the following industries:

  • Automotive (Brake pads, Gear parts, Connecting rods, Planetary carriers, Sintered Engine Bearings);

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  • Aerospace (Light weight Aluminum base structural materials, High temperature Composite materials);

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  • Cutting tools (Hard metals, Diamond containing materials);

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  • Medicine (Dental implants, Surgical instruments);

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  • Abrasives (Grinding and Polishing wheels and Discs);
  • Electrical, Electronic and Computer parts (Permanent magnets, Electrical contacts).

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Sintering in Powder Metallurgy | Green Compact | Diffusing

What is sintering in powder metallurgy process?

The operation of heating the green compact at high temperature in a controlled atmosphere (Reducing atmosphere which protects oxidation of metal powders). The Sintering increases the bond between the particles and therefore strengthens a powder metal compact. Sintering temperature and time of sintering depends on the type of powders and the strength required in a final product. The Sintering temperatures usually 0.6 to 0.8 times the melting point of powders.

01-Sintering-techniques-Powder-particles-Combining-joining

Type of powder                       Sintering Temperature            Time

Aluminium & Alloys                370 – 520 C                                  24 hrs

Copper, Brass, Bronze             700 – 900 C                                  30 Mins

Iron                                            1025 – 1200 C                              30 Mins

Stainless Steel                           1180 C                                       20 – 40 Mins

Tungsten Carbide                     1480 C                                      20 – 40 Mins

02-Sintered gears

Spark Plasma Sintering Mechanisms:

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The process of simultaneous pressing & Sintering of metal powders by high energy electric spark. This spark is discharged from capacitor bank & removes the surface contaminants from powder particles. This cause the particles to form a solid cohesive mass. Immediately after spark, the current is continued for about 10 Seconds, with high temperature which further strengthens the bond used for sintering Aluminium, Copper, Iron and Stainless Steel.

 04-Spark plasma Sintering-Complete Setup

05-SPS-Graphite Punch