Powder Metallurgy Preparation of metal powders by Atomization Electrolytic process Reduction. 15CY104: Material Technology SRM University 2
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1 Powder Metallurgy Preparation of metal powders by Atomization Electrolytic process Reduction 15CY104: Material Technology SRM University 2
2 Powder metallurgy is a term covering a wide range of ways in which materials or components are made from metal powders This processes can avoid, or greatly reduce, the need to use metal removal processes, Thereby drastically reducing yield losses in manufacture and often resulting in lower costs 15CY104: Material Technology SRM University 3
3 Thought to originally in Udayagirierected by one of the Gupta monarchs(~402 CE). In 1233 CE, It was transported to its current location. Iron Pillar located in Delhi, India, is a 7 m column in the Qutbcomplex Notable for the rust-resistant composition of the metals used in its construction. Stands as strong evidence for something to the skill of ancient Indian blacksmiths because of its high resistance to corrosion. The corrosion resistance results from an even layer of crystalline iron hydrogen phosphate hydrate forming on the high phosphorus content iron, which serves to protect it from the effects of the local Delhi climate 15CY104: Material Technology SRM University 4
4 Modern powder metallurgy technology commenced in the 1920s With the production of tungsten carbides and the mass production of porous bronze bushes for bearings. Further development took place, during the Second World War Steady growth period developed during the postwar years until the early 1960s Since then, growth of powder metallurgy has expanded more rapidly, mainly because of three potential reasons Economical processing, Unique properties and Captive processes. 15CY104: Material Technology SRM University 5
5 Primarily, the powder metallurgy process is a rapid, economical and high volume production method for making precision components from powders. However, there are a number of related consolidation techniques whereby powders can be rolled into sheet, extruded into bars, etc., or compacted isostaticallyinto parts of more involved geometry. Over the last decade, the technology of powder forging has established itself for fabricating powders into precise engineering parts which have properties comparable with those of conventional forgings. Conventional forgings Precision forgings 15CY104: Material Technology SRM University 6
6 Metal Powder Lubricants Blending Additives Loose Powder Die Compaction Cold Compaction Cold Isostatic Pressing Other Methods Rolling Extruction Explosive Compaction Hot Consolidation Hot Pressing Hot Isostatic Pressing Extrusion Pseudoisostatic Sintering Secondary Treatment Hot Forging Finished PM Parts 15CY104: Material Technology SRM University 7
7 15CY104: Material Technology SRM University 8
8 Powder metallurgy(p/m) process is many times more competitive than other fabrication methods like casting, stamping or machining. P/M is the choice when requirements for strength, wear resistance or high operating temperatures exceed the capabilities of die casting alloys. P/M offers greater precision, eliminating most or all of the finish machining operations required for castings. It avoids casting defects such as blow holes, shrinkage and inclusions. Powder injection mouldingis coming out as a big challenge for investment casting. P/M is highly competitive with fine blanking, which runs at a slower cycle than conventional stamping and higher equipment cost. Screw machines use bar stock as raw metal and the process is characterized by very poor material utilization, sometimes less than 50 %. However the P/M process is economical only when production rates are higher, since the tooling cost is quite appreciable. 15CY104: Material Technology SRM University 9
9 Any material that can be melted can be made into powder by disintegration of the liquid 15CY104: Material Technology SRM University 10
10 Aside from chemical reactivity, which may necessitate specific atmosphere or materials, the process is independent of the normal physical and mechanical propertiesassociated with the solid material. The method is being widely adopted, especially, because of the relative case of making high purity metals and prealloyedpowders directly from the melt. The basic procedure employed is to force a liquid through an orifice, possibly at a bottom of a crucible and impinge a gas or liquid stream on the emerging melt. A great deal depends on the exact design of the orifice. It may induce turbulence in the melt which atomizes the material directly and allows the impinging gas or liquid to reduce the size of the particle still faster. Classified into categories (1) Gas atomization (2) Liquid atomization (water) (3) Centrifugal atomization 15CY104: Material Technology SRM University 11
11 Gas atomization The general atomizing media are nitrogen, argon or air. Various atomization geometries are used in commercial practice. External mixing is used exclusively for the atomization of metals Internal mixing is common for the atomization of materials which are liquid at room temperature. 15CY104: Material Technology SRM University 12
12 Gas atomization The powders are typically spherical, with relatively smooth surfaces. Higher pressure and/or a smaller jet distance produce finer powder. Gas atomization pressures are typically in the range Pa to Pa at gas velocities from 50 m.s 1 to 150 m.s 1 ; Under these conditions, the particle quench rate is ~10 2 K.s 1. Such production method is used for preparing powders of the superalloys, titanium, high speed steel and other reactive metals. The method suffers from a very low overall energy efficiency (~3 %) and is expensive if inert gases other than nitrogen have to be used. 15CY104: Material Technology SRM University 13
13 Liquid (water) atomization In water atomization, a high pressure water stream is forced through nozzles to form a disperse phase of droplets which then impact the metal stream. In this method, large quantities of energy are required to supply the water at high pressure. It is estimated that the overall energy process efficiency is 4 %. This production method is significant for low and high alloy steels, including stainless steel. In general, the shapes are irregular with rough oxidized surfaces Because of oxide formation, water atomization is not likely to be used in the atomization of highly reactive metals such as titanium and the super alloys.. 15CY104: Material Technology SRM University 14
14 Liquid (water) atomization Advantages of atomized powders and more specifically, of high pressure water atomized powders are summarized by Gummeson 1) Freedom to alloy 2) All particles have the same uniform composition 3) Control of particle shape, size and structure 4) Higher purity 5) Lower capital cost. A recent innovation involves the use of synthetic oil rather than water to reduce oxidation. 15CY104: Material Technology SRM University 15
15 Liquid (water) atomization Fine particle sizes are favoured by: 1) Low metal viscosity 2) Low metal surface tension 3) Superheated metal 4) Small nozzle diameter, i.e. low metal feed rate. 5) High atomizing pressure 6) High atomizing agent volume 7) High atomizing agent velocity 8) High atomizing agent viscosity 9) Short metal stream (F) 10)Short jet length (E) 11)Optimum apex angle ( α o ). 15CY104: Material Technology SRM University 16
16 Liquid (water) atomization Particle shapes of atomized powders can be modified From almost perfectly spherical to highly irregular By controlling the processes which take place in the interval between disintegration of the liquid metal stream and the solidification of the drop. 15CY104: Material Technology SRM University 17
17 Liquid (water) atomization Sphericityof a metal powder is favoured by 1) High metal surface tension 2) Narrow melting range 3) High pouring temperature 4) Gas atomization, especially inert gas 5) Low jet velocity 6) Long apex angles in water atomization 7) Long flight paths 15CY104: Material Technology SRM University 18
18 Centrifugal atomization The basis of centrifugal atomization is the ejection of molten metal from a rapidly spinning container, plate or disc Several methods are based on centrifugal atomization. In one approach, the rotating disk method, the liquid metal stream pours onto a rapidly rotating disk that sprays the metal in all directions to produce powders. 15CY104: Material Technology SRM University 19
19 Centrifugal atomization Rotating Electrode Process (REP) The material in the form of a rod electrode is rotated rapidly while being melted at one end by an electric arc. Molten metal spins off the bar and solidifies before hitting the walls of the inert gas filled outer container Powder particles are smooth and spherical (an average diameter of~200 mm; the size range is mm). Typically, yields run to ~75% for 35 mesh powder Limitation -Tungsten contamination Rotating Electrode Process 15CY104: Material Technology SRM University 20
20 Centrifugal atomization Plasma Rotating Electrode Process (PREP) No Tungsten contamination It is important that the electrodes are precisely dimensioned and straight. This can be achieved by subjecting cold drawn rod to cross roll straightening Accurately controlled rotation of the anode is important to obtain desired range of particle size distribution. Various mechanical atomization methods -Roller atomization, Vibratory electrode atomization and Ultrasonic atomization Short Bar PREP Machine 15CY104: Material Technology SRM University 21
21 Vacuum atomization Vacuum or soluble gas atomization is a commercial batch process Based on the principle that when a molten metal supersaturated with gas under pressure is suddenly exposed to vacuum The gas expands, comes out of solution, and causes the liquid metal to be atomized Alloy powders based on Ni, Cu, Co, Fe and Al can be vacuum atomized with hydrogen Powders are spherical, clean and of a high purity compared other methods (a)trap door, (b) transfer tube (c) molten metal Production of gas turbine disks and intricate parts by injection moulding. 15CY104: Material Technology SRM University 22
22 Chemical reduction involves chemical compound most frequently an oxide, but sometimes a halide or other salt of the metal. This may be carried out: from the solid state from the gaseous state from the aqueous solution 15CY104: Material Technology SRM University 23
23 From the solid state Reduction of iron oxide with carbon or of tungsten oxide with hydrogen. Höganäs process based in the use of quite pure magnetite (Fe 3 O 4 ) ores The iron ore is reduced with a carbonaceous material Another Example Sponge iron powder production from iron ore 15CY104: Material Technology SRM University 24
24 From Gaseous state The reduction of titanium tetrachloride vapourwith molten magnesium the well-known Kroll process From Aqueous solution Precipitation of cement copper from copper sulphate solution with iron Cement copper produced are a by-product of the copper refinery industry. This cement copper is eventually melted and cast rather than used as powder for two reasons The cement copper produced as a by-product is rather impure unless special precautions are taken The powder is quite fluffy, i.e. it has a low apparent density, which is not satisfactory for many copper powder applications. 15CY104: Material Technology SRM University 25
25 From Aqueous solution The reduction of an ammoniacalnickel salt solution with hydrogen under pressure (1.38 Mpa(200 psi) ) and a temperature of C in an autoclave (hydrometallurgical method) - Sherrit Gordon process A nickel salt solution is obtained by leaching complex Cu Ni Co ores Copper is removed from the solution by precipitation as sulphide Catalyst (e.g. ferrous sulphate) is used, for the precipitation of the first nickel powder nuclei from the solution The very fine nickel powder nuclei are allowed to settle in the autoclave, the barren solution is decanted and a new batch of solution is introduced into the autoclave. The nickel powder nuclei are suspended in the solution by agitation and the nickel in the solution is reduced with hydrogen at 1.38 MPa(200 psi) and precipitated on the existing nuclei. The process permits control of the size and shape of the nickel powder being produced 15CY104: Material Technology SRM University 26
26 It is used extensively in the preparation of copper, beryllium, iron and nickel powders The method yields a high purity metal with excellent properties for conventional powder metallurgy processing The process involves the control and manipulation of many variables and in some cases is significantly more costly than other techniques. For example, electrolytic iron powder is more costly than reduced or atomized powder with the same characteristics, while electrolytic copper powder is quite competitive with reduced and precipitated types The following are the factors promoting powdery deposits: (1) High current densities (5) Avoidance of agitation; High viscosities (2) weak metal concentrations (6) Suppression of convection (3) Additions of colloids and acids (4) Low temperature 15CY104: Material Technology SRM University 27
27 It may be very difficult to produce a high purity powdery deposit at relatively fast rates economically. Consequently, in many cases the deposit is a solid and must be powdered Electrolytic deposits, powders or solids are usually very reactive and brittle. For both these reasons the material may be given a special annealing treatment. Powders formed during electrolysis have a characteristic dendriticshape; however, this could be changed substantially due to subsequent processing. 15CY104: Material Technology SRM University 28
28 Electrolytic process for making metal powders 15CY104: Material Technology SRM University 29
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