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Powder Metallurgy (P/M) Method: Make fine metal powders and sort Mix powders to get “alloy” Iron alloys most common, also Bronze Compaction Powder is pressed into a “green compact” 20,000-100,000psi pressure Still very porous, ~70% density May be done cold or warm (higher density)

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  1. Powder Metallurgy (P/M) • Method: • Make fine metal powders and sort • Mix powders to get “alloy” • Iron alloys most common, also Bronze • Compaction • Powder is pressed into a “green compact” • 20,000-100,000psi pressure • Still very porous, ~70% density • May be done cold or warm (higher density) • Sintering • Controlled atmosphere: no oxygen • Heat to .75*Tmelt • Particles bind together • Part shrinks in size • Density increases, up to 95% • Strength ~=~ Density • P/M (vs. Casting): • Mass produce small steel parts, net-shape • Less waste • Unusual “alloys” • Range of densities, porosity (adv or disadv) • Less energy use • But: Smaller parts and less complexity (2.5D) P/M net-shape gears are common, save machining time oee.nrcan.gc.ca

  2. Powder Metallurgy Slightly porous appearance is common Range of particle sizes www.buau.com.au www.parmaco.com

  3. Cermet cutting inserts for lathe Powder Metallurgy: Cermet cutting tools (Ceramic-Metal composite) www.kyocera-yashica.com.br Cermet-tipped saw blade for long life Microstructure: ceramic particles in metal matrix www.moldmakingtechnology.com www.toolbarn.com

  4. Metal filters Powder Metallurgy: Porous Metals Oil-impregnated Porous Bronze Bearings nic.sav.sk www.ondrives.com www.hd-bearing.com

  5. Powder Metallurgy: Connecting Rods www.dps-performance.com Forged on left; P/M on right

  6. Powdered Metal Transmission Gear www.chipm.com • Warm compaction method with 1650-ton press • Teeth are molded net shape: No machining • UTS = 155,000 psi • 30% cost savings over the original forged part

  7. Powdered Metal Turbine blade-disk (“blisk”): 1 piece! www.ml.afrl.af.mil

  8. Conventional Forging vs. Forging of Powdered Metal blank (2nd op) DeGarmo

  9. References DeGarmo: E.P. DeGarmo et al, Materials and Processes in Manufacturing, Wiley, 2003.

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