Powder Metallurgy. Powder-Metal Processing and Equipment 11/10/2009

Save this PDF as:
 WORD  PNG  TXT  JPG

Size: px
Start display at page:

Download "Powder Metallurgy. Powder-Metal Processing and Equipment 11/10/2009"

Transcription

1 Powder Metallurgy Powder-Metal Processing and Equipment Metal powders are compacted into desired and often complex shapes and sintered* to form a solid piece * Sinter: To heat without melting Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 17 FIGURE 17.1 (a) Examples of typical parts made by powdermetallurgy processes. (b) Upper trip lever for a commercial irrigation sprinkler made by PM. This part is made of an unleaded brass alloy; it replaces a die-cast part with a 60% cost savings. (c) Main-bearing metal-powder caps for 3.8- and 3.1-liter General Motors automotive engines. Source: (a) and (b) Reproduced with permission from Success Stories on PM Parts, Metal Powder Industries Federation, Princeton, New Jersey, (c) Courtesy of Zenith Sintered Products, Inc., Milwaukee, Wisconsin. FIGURE 17.2 Outline of processes and operations involved in producing powder-metallurgy parts. FIGURE 17.3 Particle shapes in metal powders, and the processes by which they are produced. Iron powders are produced by many of these processes (see also Fig. 17.4). FIGURE 17.4 (a) Scanning-electron microscope image of iron-powder particles made by atomization. (b) Nickel-based superalloy (Udimet 700) powder particles made by the rotating electrode process; see Fig. 17.5d. Source: Courtesy of P.G. Nash, Illinois Institute of Technology, Chicago. 1

2 FIGURE 17.5 Methods of metal-powder production by atomization: (a) gas atomization; (b) water atomization; (c) centrifugal atomization with a spinning disk or cup; and (d) atomization with a rotating consumable electrode. FIGURE 17.6 Methods of mechanical comminution to obtain fine particles: (a) roll crushing, (b) ball mill, and (c) hammer milling. FIGURE 17.7 Mechanical alloying of nickel particles with dispersed smaller particles. As nickel particles are flattened between two balls, the second, smaller phase is impressed into the nickel surface and eventually is dispersed throughout the particle due to successive flattening, fracture, and welding events. FIGURE 17.8 (a) through (d) Some common bowl geometries for mixing or blending powders. (e) A mixer suitable for blending metal powders. Since metal powders are abrasive, mixers rely on the rotation or tumbling of enclosed geometries, as opposed to using aggressive agitators. Source: Courtesy of Kemutec Group, Inc. FIGURE 17.9 (a) Compaction of metal powder to form a bushing. The pressed-powder part is called green compact. (b) Typical tool and die set for compacting a spur gear. Source: Courtesy of the Metal Powder Industries Federation. FIGURE (a) Density of copper- and iron-powder compacts as a function of compacting pressure. Density greatly influences the mechanical and physical properties of PM parts. (b) Effect of density on tensile strength, elongation, and electrical conductivity of copper powder. Source: (a) After F.V. Lenel, (b) After the International Annealed Copper Standard (IACS) for electrical conductivity. 2

3 FIGURE Density variation in compacting metal powders in various dies: (a) and (c) single-action press; (b) and (d) double-action press. Note in (d) the greater uniformity of density from pressing with two punches with separate movements compared with (c). (e) Pressure contours in compacted copper powder in a single-action press. Source: After P. Duwez and L. Zwell. TABLE 17.1 Compacting Pressures for Various Powders FIGURE A 7.3-MN (825-ton) mechanical press for compacting metal powder. Source: Courtesy of Cincinnati Incorporated. FIGURE Schematic diagram of cold isostatic pressing. Pressure is applied isostatically inside a high-pressure chamber. (a) The wet bag process to form a cup-shaped part. The powder is enclosed in a flexible container around a solid-core rod. (b) The dry bag process used to form a PM cylinder. FIGURE Capabilities, with respect to part size and shape complexity, available from various PM operations. PF = powder forging. Source: Courtesy of the Metal Powder Industries Federation. FIGURE Schematic illustration of hot isostatic pressing. The pressure and temperature variation versus time are shown in the diagram. 3

4 FIGURE A valve lifter for heavy-duty diesel engines produced from a hot-isostatic-pressed carbide cap on a steel shaft. Source: Courtesy of the Metal Powder Industries Federation. Powder-Injection Molding (An alternative to conventional compaction) Very fine metal powders are blended with a 25 45% polymer or a wax-based binder Mixture is injected into a mold at 135 o 200 o C Debinding: Molded green parts placed in oven to burn off the plastic Sinter (up to 1375 o C) Useful to make complex shapes with small wall thickness FIGURE Powder-metal components for mobile phones to achieve a flip-open feature. FIGURE An illustration of powder rolling. FIGURE Spray deposition (Osprey process) in which molten metal is sprayed over a rotating mandrel to produce seamless tubing and pipe. TABLE 17.2 Sintering Temperature and Time for Various Metals 4

5 FIGURE Schematic illustration of two mechanisms for sintering metal powders: (a) solid-state material transport; and (b) vapor-phase material transport. R = particle radius, r = neck radius, and ρ = neckprofile radius. TABLE 17.3 Mechanical Properties of Selected PM Materials TABLE 17.4 Comparison of Mechanical Properties of Some Wrought and Equivalent PM Metals (as Sintered) TABLE 17.5 Mechanical Property Comparisons for Ti-6AL-4V Titanium Alloy Secondary & Finishing Operations Coining & Sizing improve dimensional accuracy, strength, surface finish Forging of sintered preform to final desired shape produces part with good surface finish and dimensional tolerances Machining, i Grinding, Plating, Heat-treating t ti Impregnate porous PM components with oil to produce permanently lubricated parts Infiltrate a lower melting point metal to fill pores, improve corrosion resistance, tensile strength Electroplate (in some conditions) a PM part to seal surface & eliminate its permeability Design Considerations Keep shape of compact as simple and uniform as possible Provide for ejection of green compact from die without damaging the compact Make PM parts with widest acceptable tolerances Avoid very thin wall thickness Produce steps in parts if they are simple and their size doesn t exceed 15% of overall part length Press embossed or recessed letters perpendicular to the direction of pressing 5

6 (More) Design Considerations FIGURE Die geometry and design features for powder-metal compaction. Source: Courtesy of the Metal Powder Industries Federation. Make sure large flanges have generous fillets and tapers Avoid sharp corners; use chamfers & flats Form keys, keyways, etc. during powder compaction Orient notches & grooves perpendicular to pressing direction Maintain uniform wall thickness Dimensional tolerance range ±0.05 to 0.1 mm FIGURE Examples of PM parts showing poor and good designs. Note that sharp radii and reentry corners should be avoided and that threads and transverse holes have to be produced separately by additional machining operations. Source: Courtesy of the Metal Powder Industries Federation. FIGURE (a) Design features to use with unsupported flanges. (b) Design features for use with grooves. Source: Courtesy of Metal Powder Industries Federation. Process Capabilities TABLE 17.6 Forged and PM Titanium Parts and Cost Savings Can make parts from high melting point refractory metals, difficult otherwise High production rates possible on relatively complex parts using automated equipment Produce parts with good dimensional control, reducing need for machining Wide range of compositions for specialized applications Capability for impregnation & infiltration Limitations - High cost of metal powder - High cost of tooling for small production runs - Limitations on part size & shape complexity - Strength & ductility < forging 6

7 FIGURE Collection of PM parts in a commercial snowblower. Summary Net shape forming process; low size & weight; good dimensional accuracy May perform secondary & finishing operations if desired Control product quality by powder quality, process variables, sintering atmospheres Powder injection molding by mixing very fine powders with polymers, later evaporated Design considerations 7

Powder-Metal Processing and Equipment

Powder-Metal Processing and Equipment Powder-Metal Processing and Equipment Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 17 Powder Metallurgy Metal powders are compacted into desired and

More information

BMM3643 Manufacturing Processes Powder Metallurgy Process

BMM3643 Manufacturing Processes Powder Metallurgy Process BMM3643 Manufacturing Processes Powder Metallurgy Process by Dr Mas Ayu Bt Hassan Faculty of Mechanical Engineering masszee@ump.edu.my Chapter Synopsis This chapter will expose students to the sequence

More information

Metal Powder Processing

Metal Powder Processing Metal Powder Processing ver. 1 1 Powder Compaction and Sintering 2 Powder-Metallurgy (a) (c) (b) (a) Examples of typical parts made by powdermetallurgy processes. (b) Upper trip lever for a commercial

More information

Dr. M. Sayuti, ST.,M.Sc JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MALIKUSSALEH

Dr. M. Sayuti, ST.,M.Sc JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MALIKUSSALEH POWDER METALLURGY Dr. M. Sayuti, ST.,M.Sc JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MALIKUSSALEH 1- INTRODUCTION Powder metallurgy is the name given to the process by which fine powdered materials

More information

Powder Metallurgy Bachelor of Industrial Technology Management with Honours Semester I Session 2013/2014

Powder Metallurgy Bachelor of Industrial Technology Management with Honours Semester I Session 2013/2014 Powder Metallurgy Bachelor of Industrial Technology Management with Honours Semester I Session 2013/2014 TOPIC OUTLINE What Is Powder Metallurgy (P.M)? Powder Metallurgy Processes Blending And Mixing Compaction

More information

Chapter 17. Processing of Metal Powders

Chapter 17. Processing of Metal Powders Chapter 17. Processing of Metal Powders 17.1 Introduction This chapter describes the powder metallurgy (P/M) process, in which metal powders are compacted into desired and often complex shapes and sintered

More information

Chapter 18: Powder Metallurgy

Chapter 18: Powder Metallurgy Chapter 18: Powder Metallurgy ผ ช วยศาสตราจารย เร อโท ดร. สมญา ภ นะยา Reference: DeGarmo s Materials and Processes in Manufacturing 18.1 Introduction Powder metallurgy is the name given to the process

More information

Powder Metallurgy. by Haipan Salam

Powder Metallurgy. by Haipan Salam Powder Metallurgy by Haipan Salam In the sintering operation, the pressed-powder compacts are heated in a controlled atmosphere to right below the melting point (70%-90% of melting point of metals or

More information

The following steps are used in the powder metallurgy techniques:

The following steps are used in the powder metallurgy techniques: Advantages of Powder Metallurgy Virtually unlimited choice of alloys and non metallicswith associated properties. * A variety of metal or non metal powders can be used. * Refractory materials are popularly

More information

Part B. Unit8 (Class16) Powder Metallurgy. Powder Extrusion

Part B. Unit8 (Class16) Powder Metallurgy. Powder Extrusion Part B Unit8 (Class16) Powder Metallurgy Powder Production Reduction,Electrolytic deposition, Pulverization, Mechanical Alloy and othersblending of powderscompaction of Powders Punch and Die,Rolling, Extrusion,

More information

Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 12/2

Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 12/2 POWDER METALLURGY Characterization of Engineering Powders Production of Metallic Powders Conventional Pressing and Sintering Alternative Pressing and Sintering Techniques Materials and Products for PM

More information

CHAPTER 14. Forging of Metals. Kalpakjian Schmid Manufacturing Engineering and Technology Prentice-Hall Page 14-1

CHAPTER 14. Forging of Metals. Kalpakjian Schmid Manufacturing Engineering and Technology Prentice-Hall Page 14-1 CHAPTER 14 Forging of Metals 2001 Prentice-Hall Page 14-1 Forging (a) (b) Figure 14.1 (a) Schematic illustration of the steps involved in forging a bevel gear with a shaft. Source: Forging Industry Association.

More information

A SHORT NOTE ON MANUFACTURING PROCESS OF METAL POWDERS

A SHORT NOTE ON MANUFACTURING PROCESS OF METAL POWDERS INTERNATIONAL JOURNAL OF RESEARCH IN COMPUTER APPLICATIONS AND ROBOTICS ISSN 2320-7345 A SHORT NOTE ON MANUFACTURING PROCESS OF METAL POWDERS 1 R.Raja, 2 M.Rajkumar 1 Assistant Lecturer, St. Joseph College

More information

Processing of Metal Powders

Processing of Metal Powders Chapter 17 Processing of Metal Powders QUALITATIVE PROBLEMS 17.15 Why is there density variation in the compacting of powders? How is it reduced? The main reason for density variation in compacting of

More information

Methods of manufacture

Methods of manufacture 1 Methods of manufacture For Ceramics (see (b)) Crush raw materials Shape the crushed raw materials (various means) Dry & fire Apply finishing operations, as needed; to achieve required dimensional tolerances

More information

Powder metallurgy. R.D.Makwana, IT, NU

Powder metallurgy. R.D.Makwana, IT, NU Powder metallurgy History 1829 Woolaston- paper published Edison-electric light-filament 1909 Coolidge tungsten worked at elevated temperature New method of fabrication-refractory metals 1 Advantages of

More information

Metal Matrix Composite (MMC)

Metal Matrix Composite (MMC) Matrix Metal Matrix Composite (MMC) The matrix is the monolithic material into which the reinforcement is embedded, and is completely continuous. This means thatt there is apath throughh the matrix ti

More information

Materials & Processes in Manufacturing

Materials & Processes in Manufacturing Materials & Processes in Manufacturing ME 151 Chapter 18 Hot Working Processes 1 Introduction Forming of materials their recrystallization temperature Higher temperatures weaken the metal making it more

More information

Metallurgical Processes

Metallurgical Processes Metallurgical Processes Chapter Sixteen: Powder Metallurgy Dr. Eng. Yazan Al-Zain Department of Industrial Engineering 1 Introduction Powder Metallurgy (PM): is a metal processing technology in which parts

More information

Primary shaping - Powder Metallurgy

Primary shaping - Powder Metallurgy Chair of Manufacturing Technology Primary shaping - Powder Metallurgy Manufacturing Technology II Exercise 2 Laboratory for Machine Tools and Production Engineering Chair of Manufacturing Technology Prof.

More information

1. 3 Extrusion molding

1. 3 Extrusion molding 1. 3 Extrusion molding 9 Extrusion is a widely used technique, both in the field of traditional and technical ceramics. This method allows the continuous manufacture of products with a constant cross-

More information

Chapter 15 Extrusion and Drawing of Metals

Chapter 15 Extrusion and Drawing of Metals Introduction Chapter 15 Extrusion and Drawing of Metals Alexandra Schönning, Ph.D. Mechanical Engineering University of North Florida Figures by Manufacturing Engineering and Technology Kalpakijan and

More information

CONVENTIONAL POWDERED METAL COMPONENTS

CONVENTIONAL POWDERED METAL COMPONENTS CONVENTIONAL POWDERED METAL COMPONENTS ABSTRACT Powder Metallurgy (PM) has advanced considerably during the last seventy years. This paper describes the conventional press & sinter process used for manufacturing

More information

Design for Forging. Forging processes. Typical characteristics and applications

Design for Forging. Forging processes. Typical characteristics and applications Design for Forging Forging processes Forging is a controlled plastic deformation process in which the work material is compressed between two dies using either impact or gradual pressure to form the part.

More information

Chapter 14 Forging of Metals

Chapter 14 Forging of Metals Introduction Chapter 14 Forging of Metals Alexandra Schönning, Ph.D. Mechanical Engineering University of North Florida Figures by Manufacturing Engineering and Technology Kalpakijan and Schmid What is

More information

Cast steel: Group of ASTM standards for steel castings and forgings

Cast steel: Group of ASTM standards for steel castings and forgings Cast steel: Group of ASTM standards for steel castings and forgings Abstract: This group of ASTM specifications covers standard properties of steel and iron castings and forgings for valves, flanges, fittings,

More information

Metal Powder Industries Federation. Allowing Fit, Form, & Function to Drive Design

Metal Powder Industries Federation. Allowing Fit, Form, & Function to Drive Design Metal Powder Industries Federation Allowing Fit, Form, & Function to Drive Design 1 Introduction PM provides the opportunity for cost effective production of complex net shape components. 2 Considerations

More information

P/M Parts. Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No.

P/M Parts. Manufacturing Processes for Engineering Materials, 5th ed. Kalpakjian Schmid 2008, Pearson Education ISBN No. P/M Parts (a) (b) FIGURE 11.1 (a) Examples of typical parts made by powder-metallurgy processes. (b) Upper trip lever for a commercial irrigation sprinkler, made by P/M. Made of unleaded brass alloy, it

More information

A given material (shapeless or a simple geometry) Rolling, extrusion, forging, bending, drawing (plastic deformation)

A given material (shapeless or a simple geometry) Rolling, extrusion, forging, bending, drawing (plastic deformation) A given material (shapeless or a simple geometry) Primary shaping processes Metal forming processes Metal cutting processes Metal treatment processes A complex geometry (shape, size, accuracy, tolerances,

More information

Metal Forming Process. Prof.A.Chandrashekhar

Metal Forming Process. Prof.A.Chandrashekhar Metal Forming Process Prof.A.Chandrashekhar Introduction Shaping of a component by the application of external forces is known as the metal forming. Metal forming can be described as a process in which

More information

1. Definitions and classification of Metal forming processes

1. Definitions and classification of Metal forming processes 1. Definitions and classification of Metal forming processes 1.1 Introduction: Metal forming is a very important manufacturing operation. It enjoys industrial importance among various production operations

More information

LOW HEAT INPUT WELDING ALLOYS

LOW HEAT INPUT WELDING ALLOYS ASTRALOY 662 CHARACTERISTICS: An all position AC/DC electrode for high strength, crack free joining of low/medium carbon, and medium tensile steels of various compositions. Low alloy medium carbon steels,

More information

Forging die design and Forging defects

Forging die design and Forging defects Forging die design and Forging defects 1.1 Forging die-design aspects: Die design is more empirical and requires experience. Design of die depends on the processing steps, nature of work piece material,

More information

MANUFACTURING PROCESSES

MANUFACTURING PROCESSES 1 MANUFACTURING PROCESSES - AMEM 201 Lecture 8: Forming Processes (Rolling, Extrusion, Forging, Drawing) DR. SOTIRIS L. OMIROU Forming Processes - Definition & Types - Forming processes are those in which

More information

CHAPTER 2: LITERATURE SURVEY

CHAPTER 2: LITERATURE SURVEY 7 CHAPTER 2: LITERATURE SURVEY 2.1. Introduction The powder metallurgy processing is one of the oldest and economic routes for producing critical and complex shaped products [1-3]. P/M is one of the most

More information

Manufacturing Process - I

Manufacturing Process - I Manufacturing Process - I UNIT II Metal Forming Processes Prepared By Prof. Shinde Vishal Vasant Assistant Professor Dept. of Mechanical Engg. NDMVP S Karmaveer Baburao Thakare College of Engg. Nashik

More information

Isostatic Pressing. To Create Unique Engineered Materials. MPIF - HIP Council John C. Hebeisen

Isostatic Pressing. To Create Unique Engineered Materials. MPIF - HIP Council John C. Hebeisen Isostatic Pressing To Create Unique Engineered Materials MPIF - HIP Council John C. Hebeisen What is Isostatic Pressing? The use of fluid pressure to modify materials Fluid may be a liquid (water,oil)

More information

Powder Metallurgy. Science, Technology. and Materials. Anish Upadhyaya. G S Upadhyaya. Department of Materials Science and Engineering

Powder Metallurgy. Science, Technology. and Materials. Anish Upadhyaya. G S Upadhyaya. Department of Materials Science and Engineering Powder Metallurgy Science, Technology and Materials Anish Upadhyaya Associate Professor Department of Materials Science and Engineering Indian Institute of Technology Kanpur, India G S Upadhyaya Former

More information

2

2 1 2 3 4 5 6 7 Direct -Straightforward steady forward force by hydraulic ram Indirect -Has the advantage that there is no friction between billet and chamber (no movement) -Note dummy block at face of ram

More information

Manufacturing Technology II. Exercise 2. Powder Metallurgy

Manufacturing Technology II. Exercise 2. Powder Metallurgy Lehrstuhl für Technologie der Fertigungsverfahren Laboratorium für Werkzeugmaschinen und Betriebslehre Manufacturing Technology II Exercise 2 Powder Metallurgy Werkzeugmaschinenlabor Lehrstuhl für Technologie

More information

Hot Forming. Kalpakjian

Hot Forming. Kalpakjian Hot Forming Kalpakjian Hot Working: Forging Open Die Forging www.smeedwerkunica.nl Paul Berenson, www.paulb.com T.Green, WIT Forging: Heat Loss Metal near die surfaces are coolest, flow less www.freedomalloysusa.com

More information

Superconductors Processing and Equipment. Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 18

Superconductors Processing and Equipment. Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 18 Ceramics, Glasses, Superconductors Processing and Equipment Text Reference: Manufacturing Engineering and Technology, g g g gy, Kalpakjian & Schmid, 6/e, 2010 Chapter 18 FIGURE 18.1 (a) Examples of typical

More information

Effects of particle shape and temperature on compaction of copper powder at micro scale

Effects of particle shape and temperature on compaction of copper powder at micro scale Effects of particle shape and on compaction of copper powder at micro scale hao-heng hang * and Ming-Ru Wu Department of Mold and Die Engineering, National Kaohsiung University of pplied Sciences, Kaohsiung,

More information

Syllabus: Different levels of structure in materials. Relation among material processing, structure, properties, and performance

Syllabus: Different levels of structure in materials. Relation among material processing, structure, properties, and performance Syllabus: Types of materials Properties of materials Different levels of structure in materials Relation among material processing, structure, properties, and performance The main objective is to understand

More information

Bulk Deformation Processes

Bulk Deformation Processes Bulk Deformation Processes Bachelor of Industrial Technology Management with Honours Semester I Session 2013/2014 TOPIC OUTLINE What is Bulk Deformation? Classification of Bulk Deformation Processes Types

More information

Forming - Bulk Forming

Forming - Bulk Forming Forming - Bulk Forming Manufacturing Technology II Lecture 4 Laboratory for Machine Tools and Production Engineering Chair of Manufacturing Technologies Prof. Dr.-Ing. Dr.-Ing. E. h. F. Klocke Outline

More information

> RX12UF. Cobalt content w/w. Grade. Properties and recommendations. HARTMETALL ESTECH AG 6285 Hitzkirch

> RX12UF. Cobalt content w/w. Grade. Properties and recommendations. HARTMETALL ESTECH AG 6285 Hitzkirch pli > Ultra-fine grain carbides are characterized by a very high hardness and wear resistance. They are used for milling tools and drills for processing abrasive, soft and tough materials, in nozzles and

More information

We offer a broad range of bronze bushings for a variety of applications. Contact us for more information.

We offer a broad range of bronze bushings for a variety of applications. Contact us for more information. Bushings We offer a broad range of bronze bushings for a variety of applications. Contact us for more information. Suitable for demanding applications in harsh environments With or without flange Able

More information

PESIT Bangalore South Campus Hosur road, 1km before ElectronicCity, Bengaluru -100 Department of Basic Science and Humanities

PESIT Bangalore South Campus Hosur road, 1km before ElectronicCity, Bengaluru -100 Department of Basic Science and Humanities USN 1 P E PESIT Bangalore South Campus Hosur road, 1km before ElectronicCity, Bengaluru -100 Department of Basic Science and Humanities CONTINUOUS INTERNAL EVALUATION TEST-3 Date : 15/05/2018 Marks: 60

More information

Casting. Forming. Sheet metal processing. Powder- and Ceramics Processing. Plastics processing. Cutting. Joining.

Casting. Forming. Sheet metal processing. Powder- and Ceramics Processing. Plastics processing. Cutting. Joining. Traditional Manufacturing Processes Casting Forming Sheet metal processing Powder- and Ceramics Processing Plastics processing Cutting Joining Surface treatment FUNDAMENTALS OF METAL FORMING Overview of

More information

Lecture 7. Chapter 13. Rolling of Metals. The process of reducing thickness of changing the cross-section 90% of all metals produced by metalworking

Lecture 7. Chapter 13. Rolling of Metals. The process of reducing thickness of changing the cross-section 90% of all metals produced by metalworking Lecture 7 Chapter 13 Rolling Rolling of Metals The process of reducing thickness of changing the cross-section 90% of all metals produced by metalworking Changes microstructure Larger grains small grains

More information

UNIT III BULK DEFORMATION PROCESS

UNIT III BULK DEFORMATION PROCESS Hot Working of Metals UNIT III BULK DEFORMATION PROCESS Hot working is defined as the process of altering the shape or size of a metal by plastic deformation with the temperature above the recrystallisation

More information

Metal extrusion. Metal stamping

Metal extrusion. Metal stamping Metal extrusion Answer the following questions 1. In which of the following extrusion operation is friction a factor in determining the extrusion force (one best answer): (a) direct extrusion or (b) indirect

More information

2890 Ligonier St. Latrobe, PA Phone Fax Toll Free

2890 Ligonier St. Latrobe, PA Phone Fax Toll Free Your Best Choice For Carbide Components 2890 Ligonier St. Latrobe, PA 15650 Phone 724.532.3041 Fax 724.532.3043 Toll Free 800.862.7066 www.extramet.net OUR HISTORY OUR MISSION Extramet s Primary Objective

More information

Surface finish or precision. Relationship between the two types of variables is established through: Experience Experiments Modeling

Surface finish or precision. Relationship between the two types of variables is established through: Experience Experiments Modeling METAL FORMING Hot & Cold Forming: Process based on the metal ability (Plasticity) to flow plastically while remaining in solid state, without deterioration of its properties Advantages: No material waste

More information

A wide range of cold-formable steel grades and aluminium alloys are used as wire materials within a diameter range from 5 mm to 34 mm.

A wide range of cold-formable steel grades and aluminium alloys are used as wire materials within a diameter range from 5 mm to 34 mm. Cold-Formed Parts 2 ESKA manufactures complex precision cold-formed parts for applications with large and medium quantities. The highly-efficient cold- forming process ensures economic manufacture of near-net-shape

More information

Markforged: Taking a different approach to metal Additive Manufacturing

Markforged: Taking a different approach to metal Additive Manufacturing Loughborough University Institutional Repository Markforged: Taking a different approach to metal Additive Manufacturing This item was submitted to Loughborough University's Institutional Repository by

More information

An Introduction to Powder Metallurgy

An Introduction to Powder Metallurgy An Introduction to Powder Metallurgy F. THÜMMLER Dr.-Ing.habil, FIM Professor Emeritus for Materials University and Nuclear Research Centre Karlsruhe and R. OBERACKER Dr.-Ing., Central Laboratory Institute

More information

Chapter 12. Flux Cored Arc Welding Equipment, Setup, and Operation Delmar, Cengage Learning

Chapter 12. Flux Cored Arc Welding Equipment, Setup, and Operation Delmar, Cengage Learning Chapter 12 Flux Cored Arc Welding Equipment, Setup, and Operation Objectives Explain the FCA welding process Describe what equipment is needed for FCA welding List the advantages of FCA welding, and explain

More information

Working principle Equipments Process parameters MRR Electrode / Tool Power circuits Tool wear Dielectric Flushing Advantages Limitations Applications

Working principle Equipments Process parameters MRR Electrode / Tool Power circuits Tool wear Dielectric Flushing Advantages Limitations Applications Unit 3 - EDM Working principle Equipments Process parameters MRR Electrode / Tool Power circuits Tool wear Dielectric Flushing Advantages Limitations Applications Wire cut EDM Recent trends in EDM Synopsis

More information

1-Materials Science & Materials Engineering

1-Materials Science & Materials Engineering 1-Materials Science & Materials Engineering 1-1-Structure & Properties Relationship (Materials Science or Materials Engineering) Processing Structure Properties Performance Sub Atomic Atomic Sub Atomic

More information

Course Syllabus Manufacturing II

Course Syllabus Manufacturing II Islamic University-Gaza Faculty Of Engineering-Mechanical Engineering Dept. 2 nd Semester 2017-2018 Dr. Juma Y. Alaydi jalaydi@mail.iugaza.edu Course Syllabus Manufacturing II Title: EIND 4320 Manufacturing

More information

Solid-State Welding Processes. Solid State Bonding 12/2/2009. Cold Welding

Solid-State Welding Processes. Solid State Bonding 12/2/2009. Cold Welding Solid-State Welding Processes Solid-State Welding Processes Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 31 Joining takes place without fusion at the

More information

Powder Metallurgy Preparation of metal powders by Atomization Electrolytic process Reduction. 15CY104: Material Technology SRM University 2

Powder Metallurgy Preparation of metal powders by Atomization Electrolytic process Reduction. 15CY104: Material Technology SRM University 2 Powder Metallurgy Preparation of metal powders by Atomization Electrolytic process Reduction 15CY104: Material Technology SRM University 2 Powder metallurgy is a term covering a wide range of ways in which

More information

BMM3643 Manufacturing Processes Bulk Metal Forming Processes (Forging Operations)

BMM3643 Manufacturing Processes Bulk Metal Forming Processes (Forging Operations) BMM3643 Manufacturing Processes Bulk Metal Forming Processes (Forging Operations) by Dr Mas Ayu Bt Hassan Faculty of Mechanical Engineering masszee@ump.edu.my Chapter Synopsis This chapter will introduced

More information

Composite Materials. Metal matrix composites

Composite Materials. Metal matrix composites Composite Materials Metal matrix composites Introduction The properties that make MMCs attractive are high strength and stiffness, good wear resistance, high service temperature, tailorable coefficient

More information

Module 3 Selection of Manufacturing Processes. IIT Bombay

Module 3 Selection of Manufacturing Processes. IIT Bombay Module 3 Selection of Manufacturing Processes Lecture 3 Design for Bulk Deformation Processes Instructional objectives By the end of this lecture, the students are expected to learn the working principle

More information

Ceramic Processing. Engineering Materials. 7/15/2009 Ceramic Processing/S.Rattanachan 1

Ceramic Processing. Engineering Materials. 7/15/2009 Ceramic Processing/S.Rattanachan 1 Ceramic Processing Engineering Materials 7/15/2009 Ceramic Processing/S.Rattanachan 1 Ceramic Processing Ceramic powders/raw materials + Additives Mixing Forming Firing Densification Sintering Vitrification

More information

MANUFACTURING TECHNOLOGY

MANUFACTURING TECHNOLOGY MANUFACTURING TECHNOLOGY UNIT II Hot & Cold Working Forging & Rolling Mechanical Working of Metals In this method no machining process is carried out, but it is used to achieve optimum mechanical properties

More information

A Study on the Powder Forging of Aluminum Alloy Pistons

A Study on the Powder Forging of Aluminum Alloy Pistons International Journal of the Korean Society of Precision Engineering Vol. 2, No. 4, November 2001. A Study on the Powder Forging of Aluminum Alloy Pistons Jong-Ok Park 1,Chul-WooPark 1 and Young-Ho Kim

More information

Processing of Engineering Materials

Processing of Engineering Materials Unit 7: Unit code Machining and Processing of Engineering Materials A/615/1481 Unit level 4 Credit value 15 Introduction Practical articles that we see and use every day such as automobiles, aircraft,

More information

Solid-State Welding Processes

Solid-State Welding Processes Solid-State Welding Processes Text Reference: Manufacturing Engineering and Technology, Kalpakjian & Schmid, 6/e, 2010 Chapter 31 Solid-State State Welding Processes Joining takes place without fusion

More information

SME 2713 Processing of Polymers - 2

SME 2713 Processing of Polymers - 2 SME 2713 Processing of Polymers - 2 Outline 1. Introduction 2. Extrusion process 3. Injection molding process 4. Blow molding process 5. Rotational molding 6. Thermoforming 7. Compression molding 8. Transfer

More information

MSE-226 Engineering Materials

MSE-226 Engineering Materials MSE-226 Engineering Materials Lecture-7 ALLOY STEELS Tool Steels TYPES of FERROUS ALLOYS FERROUS ALLOYS Plain Carbon Steels Alloy Steels Cast Irons - Low carbon Steel - Medium carbon steel - High carbon

More information

Engineering Materials

Engineering Materials Engineering Materials Lecture 2 MEL120: Manufacturing Practices 1 Selection of Material A particular material is selected is on the basis of following considerations 1. Properties of material 1. Properties

More information

Chapter 14: Metal-Forging Processes and Equipments

Chapter 14: Metal-Forging Processes and Equipments Manufacturing Engineering Technology in SI Units, 6 th Edition Chapter 14: Metal-Forging Processes and Equipments Chapter Outline Introduction Open-die Forging Impression-die and Closed-die Forging Various

More information

ลวดเช อมพ เศษ. Weld Mold / USA. Tool and Die Alloy Welding Materials

ลวดเช อมพ เศษ. Weld Mold / USA. Tool and Die Alloy Welding Materials ลวดเช อมพ เศษ Weld Mold / USA Tool and Die Alloy Welding Materials High-strength alloys for bearing surfaces and tools that must work-harden, for the joining of cracked die sections and for applications

More information

Comparison of BS and BS EN for steel materials

Comparison of BS and BS EN for steel materials Comparison of BS and BS EN for steel materials Appendix This table only highlights the comparison of BS and BS EN on steel materials, which are relevant to plan approval. Title of BS BS BS EN Title of

More information

PLATE FORGING FOR CONTROLLING WALL THICKNESS DISTRIBUTION OF PRODUCTS

PLATE FORGING FOR CONTROLLING WALL THICKNESS DISTRIBUTION OF PRODUCTS PLATE FORGING FOR CONTROLLING WALL THICKNESS DISTRIBUTION OF PRODUCTS Ken-ichiro Mori Department of Mechanical Engineering, Toyohashi University of Technology, Japan Summary Plate forging processes for

More information

Connecting Rod Evaluation

Connecting Rod Evaluation January 2005 Connecting Rod Evaluation James R. Dale Vice President, Member and Industry Relations Metal Powder Industries Federation 105 College Road East Princeton, NJ 08540-6692 Introduction Since 1986,

More information

RAPID PATTERN BASED POWDER SINTERING TECHNIQUE AND RELATED SHRINKAGE CONTROL

RAPID PATTERN BASED POWDER SINTERING TECHNIQUE AND RELATED SHRINKAGE CONTROL RAPID PATTERN BASED POWDER SINTERING TECHNIQUE AND RELATED SHRINKAGE CONTROL Jack G. Zhou and Zongyan He ABSTRACT Department of Mechanical Engineering and Mechanics Drexel University 3141 Chestnut Street

More information

ME 4563 ME 4563 ME Introduction to Manufacturing Processes. College of Engineering Arkansas State University.

ME 4563 ME 4563 ME Introduction to Manufacturing Processes. College of Engineering Arkansas State University. Introduction to Manufacturing Processes College of Engineering Arkansas State University 1 Bulk Deformation 2 1 Rolling 3 What is Rolling? A process of reducing the thickness (or changing the cross-section

More information

Compare with Rolling process which generally produces continuous plates, sheets, shapes

Compare with Rolling process which generally produces continuous plates, sheets, shapes 1 One of oldest and most important metal working processes 4000 BC First used to make jewelry, coins, implements by hammering metals with stone Now: Large rotors for turbines Gears Bolts and rivets Cutlery

More information

Fundamentals of Metal Forming

Fundamentals of Metal Forming Fundamentals of Metal Forming Chapter 15 15.1 Introduction Deformation processes have been designed to exploit the plasticity of engineering materials Plasticity is the ability of a material to flow as

More information

voestalpine Additive Manufacturing Center Singapore Pte Ltd

voestalpine Additive Manufacturing Center Singapore Pte Ltd voestalpine Additive Manufacturing Center Singapore Direct Metal Deposition, DMD. 30 th November 2017 www.voestalpine.com voestalpine Additive Manufacturing Center. Singapore Direct Metal Deposition» Company

More information

INDEX METALS FERRIC METALS NON-FERRIC METALS WORKING WITH METALS METAL FORMING TECHNIQUES ENVIRONMENTAL IMPACT OF METAL EXTRACTION

INDEX METALS FERRIC METALS NON-FERRIC METALS WORKING WITH METALS METAL FORMING TECHNIQUES ENVIRONMENTAL IMPACT OF METAL EXTRACTION METALS INDEX METALS FERRIC METALS NON-FERRIC METALS WORKING WITH METALS METAL FORMING TECHNIQUES ENVIRONMENTAL IMPACT OF METAL EXTRACTION METALS CHEMICAL ELEMENTS FOUND IN NATURE IN SOLID STATE AT ROOM

More information

ASTM Volume 02.05, May 2017 Metallic and Inorganic Coatings; Metal Powders and Metal Powder Products

ASTM Volume 02.05, May 2017 Metallic and Inorganic Coatings; Metal Powders and Metal Powder Products 1 B136-84(2013) Standard Method for Measurement of Stain Resistance of Anodic Coatings on Aluminum 2 B137-95(2014) Standard Test Method for Measurement of Coating Mass Per Unit Area on Anodically Coated

More information

02 03 MATERIALS ENGINEERING TOOLING ALLOYS

02 03 MATERIALS ENGINEERING TOOLING ALLOYS en TOOLING ALLOYS 02 03 MATERIALS ENGINEERING TOOLING ALLOYS CONTENT 05 EXCLUSIVE PRACTICAL EXPERIENCE 06 ASP STEELS 08 CPM STEELS 10 SIGNIFICANT ADVANTAGES OF POWDER METALLURGICAL HIGH PERFORMANCE STEELS

More information

Objectives. This chapter provides fundamental background on processes of drawing of rods, wires and tubes.

Objectives. This chapter provides fundamental background on processes of drawing of rods, wires and tubes. WIRE DRAWING Objectives This chapter provides fundamental background on processes of drawing of rods, wires and tubes. Mathematical approaches for the calculation of drawing load will be introduced. Finally

More information

BZN* Compacts Tool Blanks and Inserts. Machining of Ferrous Materials

BZN* Compacts Tool Blanks and Inserts. Machining of Ferrous Materials BZN* Tool Blanks and Inserts Machining of Ferrous Materials BZN* Tool Blanks and Inserts Diamond Innovations manufactures a complete line of high quality polycrystalline CBN products for machining ferrous

More information

Introduction to PM. Marco Actis Grande

Introduction to PM. Marco Actis Grande Introduction to PM Marco Actis Grande What is PM? Materials forming technique Create powders (metallic & non-metallic) Assemble them into artefacts of desired shape Cause the powder particles to adhere

More information

Casting and Permold Product Portfolio

Casting and Permold Product Portfolio Casting and Permold Product Portfolio Sourcing and Supply Chain Solution for OEM Serving Industry For 25Yrs Our Mission is to reduce our clients total cost of ownership Sourcing Supply Chain Management

More information

J.I.C. HYDRAULIC TUBING Seamless & Welded Hydraulic Fluid Line 23 Seamless Burst Pressures & Working Pressures 24 Welded Burst Pressures 25

J.I.C. HYDRAULIC TUBING Seamless & Welded Hydraulic Fluid Line 23 Seamless Burst Pressures & Working Pressures 24 Welded Burst Pressures 25 TABLE OF CONTENTS STEEL & ALLOY ROUND MECHANICAL TUBING Drawn Over Mandrel (DOM) 3-15 Cold Drawn Seamless (CDS) 3-15 Hot Rolled Seamless (HRS) 3-15 Electric Resistance Welded (ERW) 3-15 Seamless 4130/4140

More information

Metallurgy, Alloys, and Applications p. 1 Introduction and Overview p. 3 Major Groups of Copper and Copper Alloys p. 3 Properties of Importance p.

Metallurgy, Alloys, and Applications p. 1 Introduction and Overview p. 3 Major Groups of Copper and Copper Alloys p. 3 Properties of Importance p. Preface p. vii Metallurgy, Alloys, and Applications p. 1 Introduction and Overview p. 3 Major Groups of Copper and Copper Alloys p. 3 Properties of Importance p. 3 Fabrication Characteristics p. 5 Alloy

More information

Review of Manufacturing Processes

Review of Manufacturing Processes Review of Manufacturing Processes ME 682 Dr. Han P. Bao Mechanical Engineering, ODU ME 682 Module 3 1 Engineering Materials The four major categories: Metal Plastics Ceramics Composites 1- Metals: Cast:

More information

Bulk Forming Processes

Bulk Forming Processes Bulk Forming Processes Chapter 16 16.1 Introduction Metal has been shaped by deformation processes for several thousand years Forging, rolling, and wire drawing were performed in the Middle Ages The Industrial

More information

Bulk Forming Processes

Bulk Forming Processes Bulk Forming Processes Chapter 16 16.1 Introduction Metal has been shaped by deformation processes for several thousand years Forging, rolling, and wire drawing were performed in the Middle Ages The Industrial

More information

Lecture 9 - Manufacturing in Engineering

Lecture 9 - Manufacturing in Engineering Introduction Dr. Carolyn Skurla Speaking Slide 2 Process Selection Choice depends on: The material from which the component is to be made. The size, shape, and dimension tolerances for the component. The

More information

Introduction to manufacturing

Introduction to manufacturing Corso di Studi di Fabbricazione 1 Introduction to manufacturing 1 MANUFACTURING - TECHNOLOGICALLY IMPORTANT Technology provides the products that help our society and its members to live better What do

More information