Contents Contributor contact details Woodhead Publishing Series in Metals and Surface Engineering xi xv Part I Forming and shaping of metal powders 1 1 Advances in atomisation techniques for the formation of metal powders 3 J. Du n k l e y, Atomising Systems Limited, UK 1.1 Introduction 3 1.2 Atomisation techniques 5 1.3 Problems and advances in gas atomisation 9 1.4 Problems and advances in water atomisation 14 1.5 Centrifugal atomisation 15 1.6 Other atomisation techniques 17 1.7 Conclusion 17 1.8 References 17 2 Forming metal powders by electrolysis 19 G.Z. Ch e n, University of Nottingham, UK 2.1 Background of electrometallurgy and powder metallurgy 19 2.2 Principle and main technological prospects for the FFC Cambridge process 22 2.3 Production of metal powders by the FFC Cambridge process 26 2.4 Direct route from oxide precursors to alloyed powders 33 2.5 Conclusions and future trends 38 2.6 Acknowledgement 39 2.7 References 39
vi Contents 3 Mechanochemical synthesis of nanocrystalline metal powders 42 C. Su r y a n a r a y a n a, University of Central Florida, USA, and E. Iva n o v, Tosoh SMD, Inc., USA 3.1 Introduction 42 3.2 Mechanochemical processing 43 3.3 The process 47 3.4 Grain size and process variables 54 3.5 Displacement reactions 58 3.6 Consolidation 61 3.7 Powder contamination 62 3.8 Conclusions 65 3.9 References 66 4 Plasma synthesis of metal nanopowders 69 I. Ch a n g, University of Birmingham, UK 4.1 Introduction 69 4.2 Potential benefits and applications of metal nanopowders 69 4.3 Electrical arc discharge synthesis of metal nanopowders 70 4.4 Conclusions 82 4.5 References 83 5 Warm compaction of metallic powders 86 A. Si m c h i and A.A. Noj o o m i, Sharif University of Technology, Iran 5.1 Introduction 86 5.2 Warm compaction process 90 5.3 Properties of warm compacted parts 98 5.4 Materials and applications 100 5.5 Future trends and concluding remarks 105 5.6 References 105 6 Developments in metal injection moulding (MIM) 109 I. To d d and A.T. Si d a m b e, University of Sheffield, UK 6.1 Introduction to metal injection moulding 109 6.2 Powders for metal injection moulding 111 6.3 Binders for metal injection moulding 115 6.4 Mixing and feedstock analysis 118 6.5 Injection moulding 122 6.6 Binder removal (debinding) 126 6.7 Sintering 133 6.8 Post-sintering 135 6.9 Applications and design 138 6.10 Conclusion 144 6.11 References 144
Contents vii Part II Materials and properties 147 7 Advanced powder metallurgy steel alloys 149 H. Da n n i n g e r and C. Gi e r l-mayer, Vienna University of Technology, Austria 7.1 Introduction 149 7.2 Composition of advanced pressed and sintered steel components 151 7.3 Manufacturing routes for sintered steel components 155 7.4 Properties, microstructures and typical products 173 7.5 Powder injection moulded steel components 186 7.6 Powder metallurgy tool steels 190 7.7 Trends in ferrous powder metallurgy 195 7.8 Acknowledgements 196 7.9 Further reading 196 7.10 References 198 8 Powder metallurgy of titanium alloys 202 F. H. Fr o e s, Consultant, USA 8.1 Introduction 202 8.2 Powders 204 8.3 Near net shapes 209 8.4 Additive layer manufacturing and powder injection molding 222 8.5 Spraying and research-based processes 231 8.6 Future trends 236 8.7 Acknowledgements 238 8.8 References 239 9 Metal-based composite powders 241 N. Ll o r c a-is e r n and C. Ar t i e d a-gu z m á n, Universitat de Barcelona, Spain 9.1 Introduction 241 9.2 Metal-based composite powder production 243 9.3 Copper- and aluminium-based composite powder systems 248 9.4 Other metal-based composite powders 257 9.5 Applications 262 9.6 Future trends 263 9.7 References 264 10 Porous metals: foams and sponges 273 R. Go o d a l l, The University of Sheffield, UK 10.1 Introduction 273
viii Contents 10.2 Powder processing: partial sintering and space holders 276 10.3 Powder processing: gas entrapment and additive layer manufacturing 284 10.4 Properties of porous metals 288 10.5 Prediction of porous metal properties 294 10.6 Future perspectives 298 10.7 References 299 11 Evolution of microstructure in ferrous and nonferrous materials 308 H. Da n n i n g e r, C. Gi e r l-mayer and S. St r o b l, Vienna University of Technology, Austria 11.1 Introduction 308 11.2 Metallographic preparation techniques for powder metallurgy products 309 11.3 Microstructures of ferrous powder metallurgy materials 319 11.4 Non-ferrous materials 339 11.5 Trends in microstructures of powder metallurgy products 352 11.6 Acknowledgements 354 11.7 Further reading 354 11.8 References 355 Part III Manufacturing and densification of powder metallurgy components 359 12 Microwave sintering of metal powders 361 D. Ag r a w a l, Pennsylvania State University, USA 12.1 Introduction and background 361 12.2 Sintering of metallic powders 364 12.3 Bulk metal processing 369 12.4 Microwave metal interaction: mechanism(s) 373 12.5 Future trends 375 12.6 Further reading 376 12.7 References 377 13 Joining processes for powder metallurgy parts 380 C. Se l c u k, Brunel Innovation Centre, UK 13.1 Introduction 380 13.2 Welding processes for powder metallurgy parts 382 13.3 Other joining processes for powder metallurgy parts 390 13.4 Discussion 393
Contents ix 13.5 Conclusions 396 13.6 References 397 14 Process optimization in component manufacturing 399 G.M. Lee, Pusan National University, South Korea, and S.J. Pa r k, Pohang University of Science and Technology, South Korea 14.1 Introduction 399 14.2 Formal optimization 400 14.3 Optimization in the die compaction process 401 14.4 Powder injection moulding optimization 406 14.5 Sintering optimization 416 14.6 Design optimization of steady-state conduction 423 14.7 Conclusions 432 14.8 References 433 15 Non-destructive evaluation of powder metallurgy parts 437 C. Se l c u k, Brunel Innovation Centre, UK 15.1 Introduction 437 15.2 Need and incentive for NDT 438 15.3 Problem/approach concept 441 15.4 Quality control by digital radiographic (DR) inspection in production 443 15.5 Challenges in relation to the state-of-the-art 444 15.6 Real-time on-line powder metallurgy parts inspection 449 15.7 Prior art in relation to radiography of particulate matter and near net-shape parts 451 15.8 Summary 452 15.9 References 454 16 Fatigue and fracture of powder metallurgy steels 455 N. Ch a w l a and J.J. Wi l l i a m s, Arizona State University, USA 16.1 Introduction 455 16.2 Fracture behavior 458 16.3 Fatigue behavior 464 16.4 Residual stress effects on fatigue 473 16.5 Constitutive behavior of microstructural constituents 477 16.6 Summary 487 16.7 Acknowledgments 487 16.8 References 487
x Contents Part IV Applications 491 17 Automotive applications of powder metallurgy 493 P. Ra m a k r i s h n a n, Indian Institute of Technology Bombay, India 17.1 Introduction 493 17.2 Powder metallurgy parts 494 17.3 Materials 505 17.4 Innovative powder metallurgy products 508 17.5 Emerging trends 511 17.6 Conclusions 517 17.7 References 517 18 Applications of powder metallurgy in biomaterials 520 M. Br a m, Institute of Energy and Climate Research, Germany, T. Eb e l and M. Wo l f f, Institute of Materials Research, Germany, A. P. Cy s n e Ba r b o s a, Universidade Federal do Rio Grande do Norte, Brazil and N. Tu n c e r, Anadolu University, Turkey 18.1 Introduction 520 18.2 Challenges of powder metallurgy biomaterials 521 18.3 Production of powder metallurgy biomaterials 526 18.4 Specific properties of powdered titanium and titanium alloy biomaterials 533 18.5 Specific properties of other powder metallurgy biomaterials 538 18.6 Case studies 543 18.7 Conclusions and future trends 547 18.8 Further reading 549 18.9 References 549 19 Applications of powder metallurgy to cutting tools 555 J. Ko n s t a n t y, AGH University of Science and Technology, Poland 19.1 Introduction 555 19.2 Tool design and composition 557 19.3 Diamond tool fabrication 568 19.4 Application of powder metallurgy diamond tools 574 19.5 Latest trends and developments 581 19.6 References 584 Index 587