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It The reasons with basic topics alloys, has lecture materials, materials no Powder (PM) Beginners Metallurgy for ( prime the unique understanding of PM ( economic microstructures PM Powder target covers drivers background ) processes is ( and captive offering to impor Metal EuroPM2017, Milan, October 2, 2017, 14:00 2017, 2, October Milan, EuroPM2017, com ) give . are of ), An Introductory Lecture An Introductory - - - Powder Metallurgy Solutions Wuppertal, Germany Dr.Volker Arnhold - 15:30 1 Powder Metallurgy (PM) for Beginners • • • • • • Materials: Materials: tool Steels, steels, super alloys, aluminum, MMC processes), furnace and press technologies (incl. tool production) (Aluminum), gear rolling, metallic filters, Topics experiences:/ Materials research, full process chain of press sinter / Responsibilities: Technology Metallurgy 31 years engaged in Powder Metallurgy starting at the Krebsöge Group 1981 and from 1997 Diploma Physics + PhD at Münster,WWU Institute Metal of Research Born 1949 Wuppertal,in Germany - Management, Quality,R&D, Health and Safety, Innovation Management ...... Powder Metallurgy Solutions i ntegration ntegration modeling,of CAD systems, simulation and testing (parts and Wuppertal, Dr.Volker Arnhold (volker@arnhold Germany - pm.de) … / forge / MIM, spray compaction MIM,forge / / – 2012 2012 GKN at Powder 2 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (HIP) Pressing (Press Sinter) and Compaction Axial Process Sintering PowderProduction Most videos, shown this in presentation, can be found on YouTube 3 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (HIP) Pressing (Press Sinter) and Compaction Axial Process Sintering PowderProduction 4 Powder Metallurgy (PM) for Beginners to high / full Density /full to high Powders Metal of Processing the for Methods Press, MIM, Print 3D and Sinter (via (via Press and Sinter) Powder Forging HIP ASM Handbook, Vol. Powder7, p. Metallurgy, Manufacturing Additive bonding of its particles. strength by the metallurgical purpose of increasing its main constituent, for the below the melting point of the compact, at a temperature treatment of a powder or Sintering is the thermal Definition of Sintering (ISO): 13 5 Powder Metallurgy (PM) for Beginners Why using PM 2. 1. special properties. special the of portion good a maintain PM times). deformation, (temperatures, processes conventional applyingby destroyed be maywhich properties, alloying), mechanical or solidification (rapid production powder e.g. processes, PM specific the via achieves structures... porous refractories, magnets, metals, hard e.g. method: other anyby manufactured be cannot The material The Properties: Technology - processes are able to able are processes – ? - 2. 1. Manufacturing / 3 D Printing). 3 D / Manufacturing for Additiveespecially holds (This all at methods other by manufactured be cannot which geometries, generateto Capable, CIPor HIP...)). (axial, compaction shape net MIM, (e.g. processing casting forming, / hot cold (machining, processes production conventional the to compared advantages economical the alternative with the superior the with alternativethe PM is PM Geometry: …) by applying net shape net applyingby …) as a net shape net a as – process, 6 Powder Metallurgy (PM) for Beginners Why using PM Technology ? ASM Handbook, Vol. Powder7, 9 p. Metallurgy, 7 Powder Metallurgy (PM) for Beginners Material Courtesy Courtesy Kobe Steel and Energy The better alternative C onsiderations The old fashioned way 8 Powder Metallurgy (PM) for Beginners Material EPMA, VisionEPMA, 2025, p. 7,www.epma.com and Energy C onsiderations Press and Sinter 9 Powder Metallurgy (PM) for Beginners Material Courtesy Courtesy Kobe Steel and E nergy The better alternative C onsiderations The old fashioned way 10 Powder Metallurgy (PM) for Beginners Material Powder Metallurgy, 2012 vol. vol. p. 2012 55, 14 Metallurgy, Powder Manufacturing, PMin Consumption Energy Arnhold, Kruzhanov, Volker Vladislav and • • • operations is high specific components A and individual studies in literature The numbers are based on public domain data (e.g. industry reports) raw materials (powder, steel, ingot) These values include the energy consumption for the production of the E generally validcomparison nergy mech. Bearbeitung Pulvermetallurgie Metallurgy Machining Schmieden Forging Casting Powder Powder C Gie onsiderations ß en 0 – the the scatter between the processes and different 4 is is nearly impossible without focusing on kWh/kg 8 Press and Sinter 12 16 11 Powder Metallurgy (PM) for Beginners Euro PM2011, Barcelona, October October 10 PM2011,Barcelona, Euro Manufacturing, PMin Consumption Energy Arnhold, Kruzhanov, Volker Vladislav (GKN Sinter Metals Sinter(GKN differentPM Operations in Consumption Energy – 26 operations) 26 MIM, Stainless Bronze, Filters,Steels… Powder Aluminum,Forging, MIM, Special processes / materials lead very the to range:high 12 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing HIP ) 13 Powder Metallurgy (PM) for Beginners Key PM Developments Powder Metallurgy, p. Metallurgy, Powder Vol. 7, ASMHandbook, 3 14 Powder Metallurgy (PM) for Beginners Key PM (1826 Developments - 1865) 15 Powder Metallurgy (PM) for Beginners Key PM (1878 Developments - 1900) 16 Powder Metallurgy (PM) for Beginners Key PM (1920iesDevelopments ) 17 Powder Metallurgy (PM) for Beginners Key PM (1920iesDevelopments ) 18 Powder Metallurgy (PM) for Beginners Key PM (1920iesDevelopments ) 19 Powder Metallurgy (PM) for Beginners Key PM (1930iesDevelopments ) via via www.epma.com 20 Powder Metallurgy (PM) for Beginners Key PM (1930iesDevelopments ) 21 Powder Metallurgy (PM) for Beginners Key PM (1950iesDevelopments ) 22 Powder Metallurgy (PM) for Beginners Key PM (1950iesDevelopments ) 23 Powder Metallurgy (PM) for Beginners EuropeanPM today: Productionin kt 24 Powder Metallurgy (PM) for Beginners EuropeanPM today: Productionin Billion € 25 Powder Metallurgy (PM) for Beginners EU isthelargest(by PMsectorvalue) globally* * If we separate Asia Pacific and Japan and Pacific Asia* separate we If 26 Powder Metallurgy (PM) for Beginners The PowderMetallurgy TechnologyPortfolio Courtesy GKN Courtesy Metals Sinter 27 Powder Metallurgy (PM) for Beginners History ofthe ‘PM tree’ as coveredby EPMA 28 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing HIP ) 29 Powder Metallurgy (PM) for Beginners Chemical Methods: ElectrolysisChemical • • • • • The powders are irregular porous and show dendritic shape. dendritic show and porous irregular are powdersThe powder.a form to and annealed screened ground, dried, is washed, deposit cathode the deposition, After cathode. loose A a ensures agitation and minimal electrolytes viscosity using high bath warm thedeposition drives process. voltage externalThe cathode. the at deposited anode and dissolved the is at material rawThe 30 Powder Metallurgy (PM) for Beginners • • • • • Chemical Methods: CarbonylChemicalProcess steels. in the of used MIM are alloyed widely manufacturing low powders nickel and iron Carbonyl sintered parts. additive. and press classical Exceptalloying Ni, popular for is a which for cannot and be used of Because flowabilityshow a size, powders low verysmall the carbonyl micrometers). (< very small fewand spherical purity powders, are high usually powders Carbonyl CO.powder and metal 43 and carbonyl) state. in the temperatures (103 Both are compounds of Because liquid boiling their low with monoxide,iron carbon pentacarbonyl or nickel tetracarbonyl are formed. at pressure high react under temperatures elevated on oxide) ores When or nickel (based iron ° C (Ni - carbonyl)), they can be easily purified by distillation. Both decompose by Both to decompose be easily purified carbonyl)), they distillation. can Fe (CO) Fe + 5 CO 5 Fe + 5 CO Fe (CO) 5 Ni(CO) Ni+ 4 CO 4 Ni + 4 CO Ni(CO) 4 ° C (Fe - 31 Powder Metallurgy (PM) for Beginners Courtesy Höganäs AB Höganäs Courtesy Chemical Methods: SpongeChemicalIron Process 32 Powder Metallurgy (PM) for Beginners • • • Melt Atomization(Water): Irregular Powder 250 micrometer). 250 (mostly between 50 and size rather distribution wide a and shape irregular an The havepowders solidification. rapid and forcing disintegration the against melt stream, jets water are directed streams. High pressure bymultiple waterjets from is disintegrated scrap) The molten (starting metal process. for the press and sinter steel powders alloyed) (low the of iron production and method for most applied Water is the atomization 33 Powder Metallurgy (PM) for Beginners • • • • PowderPreparation during transport transport during handling: and to segregation processes withof bonding special avoid applied Severalmethods of mixing these verydifferent constituents are (different behavior types of wax). A to has (friction) lubricant compaction to the be added improve (graphite). (atomized or electrolytic), Ni(carbonyl), Mo (electrolytic) + C Typical elements press for parts sinter and Cu are alloying density.high The latter often is quite used PowderForging. for mixes.Fullypre For the production of structural parts weneed Fe • • • • • Hybridbonding (an intelligent combination of the above possibilities). density of elements (strongly expanding during the last years). Chemical bonding is applicable depending on powder size and Diffusion bonding shows excellent properties, but adds to the cost. compositions. Less homogeneous structures. Free admix for less critical parts or onlysome special alloy during processing). Prealloying (limited use, but applied quite often for parts to be forged - alloyed steel powder is too hard to be compacted is too to alloyed steel powder hard be compacted to - alloy powderalloy 34 Powder Metallurgy (PM) for Beginners PowderPreparation: The Benefit of Bonding 35 Powder Metallurgy (PM) for Beginners Melt Atomization (Gas): Process • • • • each each surface. other or with a solid before The theyinto rapidly droplets freeze come contact with ligaments viadisintegrated The metal flow forms surface acts as a (to safe coating reduce risk the of explosion). also sometimes (e.g. air for Aluminum) react the withmetal: so, inert (Ar,gases He), or nitrogen The gas to used atomize the molten metal should normally not the break The formation involves atomization of a powder bygas metal - up up gas. stream of the bythe expanding liquid rapidly first first a thin hollow sheet hollow thin sheet and is then ellipsoids spheres. and ellipsoids – in this this case in the oxide 36 Powder Metallurgy (PM) for Beginners • • • • Melt Atomization (Gas): SphericalPowder additional treatments treatments necessary.are additional gas, no the classification, normally So, veryprocess clean powders. besides achieves As, different to atomization, contamination from the water there is no or verylimited atomizing for flowability. The is excellent which of shape the good spherical, is particles usually Pressing) or Molding or to diameter Additive Manufacturing) a higher can particle in the size be e.g. The powder tailored of range to a it the size wideis possible distribution range. control overparticle of the configuration of jets, gas, pressure thickness volume atomizing and of melt stream, etc. several Byparameters varying – melt temperature and additives, design melt temperature possible and 5 50 - 70 – μm (for Metal Injection μm (for Injection Metal 350 μm (for Hot Isostatic μm (for Hot Isostatic – 37 Powder Metallurgy (PM) for Beginners Powders:Different Sizes,and Prices Shapes 38 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal HIP Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing HIP ) 39 Powder Metallurgy (PM) for Beginners Sintering Equipment:SinteringContinuousFurnace Width Width 300 to 1000 mm Working temperature up to 1150 Belt Furnace ° C 40 Powder Metallurgy (PM) for Beginners Sintering 1: Sinteringe.g. PressSinter and (d Fe ≈50 – 150 μ ) 41 Powder Metallurgy (PM) for Beginners Sintering 2: SinteringVacuum / Batch Process 42 Powder Metallurgy (PM) for Beginners Sintering 2: SinteringExample MIM (d < 50 μ ) 43 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (HIP) Pressing (Press Sinter) and Compaction Axial Process Sintering PowderProduction 44 Powder Metallurgy (PM) for Beginners Press and Sinter Process Think Think – Materials and Processes, GKN Sinter Processes, Metals, GKNand www.gkn.com Sinter Materials 45 Powder Metallurgy (PM) for Beginners Compaction PressesCompaction 46 Powder Metallurgy (PM) for Beginners Press and Sinter Process: Pressing Courtesy GKN Courtesy Metals Sinter 47 Powder Metallurgy (PM) for Beginners Press and Sinter Process: Sintering Courtesy GKN Courtesy Metals Sinter 48 Powder Metallurgy (PM) for Beginners Press and Sinter Process: Sizing Courtesy GKN Courtesy Metals Sinter 49 Powder Metallurgy (PM) for Beginners Press and Sinter Process: GearRolling Courtesy GKN Courtesy Metals Sinter 50 Powder Metallurgy (PM) for Beginners Press and Sinter Process: PowderForging Courtesy GKN Courtesy Metals Sinter 51 Powder Metallurgy (PM) for Beginners Propertiesof Press SinteredandSteels Think Think – Materials and Processes, GKN Sinter Processes, Metals, GKNand www.gkn.com Sinter Materials 52 Powder Metallurgy (PM) for Beginners TypicalPress SinteredandParts 53 Powder Metallurgy (PM) for Beginners Valve parts PM Sinter and Press Famous seat insert insert thermal thermal expansion, good machinability, 0.02 kg highresistance, conductivity,thermal low net Near shape rings, high wear temperature (VSI) (1954 (VSI) (1954 ) 54 Powder Metallurgy (PM) for Beginners Combustion engines with engines Combustion Market and application for VSIfor application and Al Aluminium engine block engine Aluminium : Hit ai in T 3 and th devel T resul be te ha me 35 di Co VSI Hitach mi A VSI pa pi im in part ty de be T 3.1 dom hol perform pr B req man th resp te for Hitachi Powdered Metals TechnicalReport No. 6 (2007) HideakiKawata, Kunio Maki,Recent Trends Heatin Resistant/Wear Resistant Sintered Alloys, m rt c s n p erm erm a o e s r s 0M c proved th pe - h t chi d t n e u i duct i co n m . r p h b i i g ght ect n wea u
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l 56 Powder Metallurgy (PM) for Beginners 3. FamousPM competitive pricing, 0.3 fatigue strength and ductility,machinability, Net shape, parts: Main parts: vertically compacted component, high – 1.5 1.5 kg B earing C ap (1990 www.gkn.com ) 57 Powder Metallurgy (PM) for Beginners MBC – Function andFunction design Courtesy Courtesy Automotive Automotive Engines, PM Terry CadlePowder alt., et Metallurgy Main Bearing Caps for GKN GKN SinterMetals 2 TECNashville, ‘93, TN, May 1993 Courtesy Courtesy Automotive Engines,PM forCaps et alt.,BearingCadle MainMetallurgyPowder Terry GKN GKN SinterMetals 2 TEC ‘93, TEC1993May Nashville,TN, 58 Powder Metallurgy (PM) for Beginners MBC – A very q uick uick into Start Realization machining operations machining savings Tremendous Metal Powder Report, July/August 1994 in 59 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing HIP ) 60 Powder Metallurgy (PM) for Beginners HIP Process, schematically 61 Powder Metallurgy (PM) for Beginners HIP Process : Animation 62 Powder Metallurgy (PM) for Beginners HIP Equipment 63 Powder Metallurgy (PM) for Beginners HIP Process, Pressureand Temperature Cycles 64 Powder Metallurgy (PM) for Beginners HIP versusForged StainlessSteels 65 Powder Metallurgy (PM) for Beginners TypicalHIP Products 66 Powder Metallurgy (PM) for Beginners HIP: ComponentProcess / CapsuleDesign 67 Powder Metallurgy (PM) for Beginners HIPStudies Case(1) 68 Powder Metallurgy (PM) for Beginners HIPStudies Case(2) 69 Powder Metallurgy (PM) for Beginners HIPStudies Case(3) 70 Powder Metallurgy (PM) for Beginners HIP for Healing’‘Defect (for PM and NonPM) 71 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing HIP ) 72 Powder Metallurgy (PM) for Beginners The MIM Process 73 Powder Metallurgy (PM) for Beginners MIM MIM Process: Two+ SinteringStep Debindering Molding 1 Solvent Debindering 2 Thermal Debindering + Sintering 74 Powder Metallurgy (PM) for Beginners Typical MIM Microstructure 75 Powder Metallurgy (PM) for Beginners Typical MIM Parts 76 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? ConclusionsandOutlook Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing HIP ) 77 Powder Metallurgy (PM) for Beginners AM: Different Process Technologies 78 Powder Metallurgy (PM) for Beginners AdditiveManufacturing: Technologies • • Direct Direct bed technology: Powder • • • • • • • • • • is known from surface coating or surface repair, where also the material can be fed by a wire.a byfed be can material repair,the also surface or where coating surface from is known multi a by positioned nozzle a through is deposited material molten (LMD)) Deposition Melt Laser called (also process DED the During to MIM). (similar step infiltration an by followed sometimes sintering, and debindering viastep a followingin place takes solidification part metal The ‘green’a in state. are as they bed, powderthe from carefully removed are then which formed, are parts until is repeated operation The nozzle. printer the through fed binder a to thanks is agglomerated powder the platform, build the on layer a powder applyingAfter 3D The etc.) plate, base / offsupports cut of (cleaning, necessaryare operations additional Some bed. powder the from is removed part built the part), the of height the on (depending cycles 1000 fewa After is repeated. operation melting beam energy The 100 to 20 by loweredis platform the Then powder.of layerthe melts selectively(EBM) beam electron or (LBM) beam laser Beam e nergy deposition (DED): deposition nergy - based powder bed systems bed powder based p rinting process is an indirect process covering 2 steps: 2 covering process indirect an is process rinting : A powder layer is first distributed on a building platform and a and platform building : a on Adistributed first is layer powder - axis arm and solidifies on the specified surface. The process The surface. specified the on solidifies and arm axis μm and a new powder layer is applied. layer powdernew a and 79 Powder Metallurgy (PM) for Beginners The AM Process, schematically 80 Powder Metallurgy (PM) for Beginners AM Technologies:LBM andEBM 81 Powder Metallurgy (PM) for Beginners AM Technologies:Inkjet Printing(3 DPrinting) Similar Similar to MIM 82 Powder Metallurgy (PM) for Beginners AM Technologies: Direct Energy Deposition (DED) 83 Powder Metallurgy (PM) for Beginners The AM Process: Equipment1 84 Powder Metallurgy (PM) for Beginners The AM Process: Equipment2 Courtesy Courtesy A dditive dditive I ndustries 85 Powder Metallurgy (PM) for Beginners AM: ProcessMain Steps 86 Powder Metallurgy (PM) for Beginners AM: TopologyOptimization Classical CAD Classical Model CAD Topology Optimization Courtesy GKN Courtesy Metals Sinter ‘Bionic ‘Bionic Design’ 87 Powder Metallurgy (PM) for Beginners P ros andof Cons AM: The Benefits • • • • • tools and longer logistical process tools and process longer logistical chains. hours (also e.g. ‘on site’ at remote locations or ships) without Short production cycle time: complex parts by layer in layer a few precious metals). Net shape process less meaning raw material consumption (e.g. assembly operations. parts designed and built into one. Reduction of numerous New functions such as complex internal channels or several is only there, where it needs to be. design / ‘bionic’ structures or by designing parts, where material Light weight structures, made possible either by the use of lattice machining and other PM processes. Increased design freedom versus casting, conventional 88 Powder Metallurgy (PM) for Beginners P ros andof Cons AM: The Challenges • • • • • Printing may be also a solutions in such cases. Difficult to require alloys weld specific approaches. But: 3D Non metals weldable cannot be processed by beam methods. possible. For small size parts series up to 25.000 parts/year are already productivity. is a constant progress foreseeable improving the machine The process not is relevant for mass production. Anyhow, there AM processes are generally suitable for unitary or series. small rate it can and be slow costly. Larger sizes to be expected by LBM. But due to the build low soon. standard powder bed systems. Larger dimensions come will to a powder bed size of approximately 250x250x250 mm for Today the part size in case of powder bed technology limitedis 89 Powder Metallurgy (PM) for Beginners The AM Process: AM Parts (1) LBM EBM 90 Powder Metallurgy (PM) for Beginners The AM Process: AM Parts (2) DED 3 3 D Printing 91 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? Conclusions Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction and Pressing ( Pressing Outlook HIP ) 92 Powder Metallurgy (PM) for Beginners 1. Introduction: Why PM 2. 1. scrap More highest complex PM metals, There offers than is material ceramics, no sustainability components 90 other the % best yield of way magnets, the ! - with from economical e structures Fe . g . - the powder refractories many reactive lowest … materials processes are metals, energy (W, produced Mo, combining highly consumption to Nb from generate … porous ), hard iron the . 93 Powder Metallurgy (PM) for Beginners 2 . AM MIM HIP The Press Porous Hard R Pt Fe or Historically efractories : A Quick History ofPM : process : : : advanced metals and metals 2010 1990 1980 Sinter materials (e (W, PM ff ff ff . / g . . . self . Mo, processes parts WC solutions lubricating Nb Co) technology at .. ) : the have are respective bearings relatively : been : applied times young 1935 1920 1920 1900 19 3000 : to th : century manufacture ff ff ff ff B ...... C . difficult to melt 94 Powder Metallurgy (PM) for Beginners 3.1 4. 3. 2. 1. PowderProduction Powder grade on same Process process, The over method, Many particle a production alloy or methods wide cost cleanliness, high and as (e it range size influence powder . starts purity, g . : can stainless of . 200 from aerospace water material be μm properties the scrap applied product steel) atomized properties, . certification 1 influence can 0 for cost μm, vary making Fe substantially water particle - powder from powder or powder ‘normal’ or 10 size gas is cost to . . and 150 a … atomized, Depending . . The very shape € /kg price sustainable depending can standard on for differ the the 95 Powder Metallurgy (PM) for Beginners 3.2 4. 3. 2. 1. Sintering ProcessSintering applied respective Atmospheres controlled The are Depending bronze hard Sintering applied cycle metals, … . . ) is can cooling . . reactivity on the press combine are material core . chosen and with process debindering, and sinter gases according process structural for . So, many sintering, quite continuous to parts PM the often products heat (Fe materials vacuum or - base, treatment batch : refractories, aluminum, has and furnaces and/or to their be 96 Powder Metallurgy (PM) for Beginners 3.3 3. 2. 1. 6. 5. 4. several The 2 The low realized complexity Prime alloys, metals The after shape The economic Axial kg Axial Compaction (Press CompactionAxialand Sinter) . additional volumes process process parts’ compaction compaction bronze target and to millions in achieve forming a weights many net and is are requires … machining) is applied per ) shape . (for normally high other good process a year is are handling reasonable powders component precision, for the alloy . in . mechanical from . structural the most materials and range a showing few combined green transport) (i common . parts e thousand . from (steels, no properties irregular strength in or . 1 hard g very with and Al to to - 97 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. 3.4 AM density additional For few Typical inclusions uniformity fill HIP sintering HIP HotIsostatic (HIP) Pressing components defect kg the combines needs to PM press is more container . healing and process somehow spherical, HIP and pressure than avoid parts (no sinter HIP 10 e canning completely ‘hidden’ are . very g any is tons . and parts, often in for clean contamination . the temperature necessary!) in castings, MIM applied range the powders with parts process from as high high . . and So an or to a . 98 Powder Metallurgy (PM) for Beginners 3.5 5. 4. 3. 2. 1. (sometimes) MIM complex time/temperature batch Sintering filling improve spherical MIM the investment The molding MIM Metal Injection(MIM) Molding more parts combines behavior prime needs or with flowability debindering economic in are continuous powders casting . MIM the competing small in spherical the properties cavities can cycle . of complexity solution : In process below the ( be 5 furnace general adapted . feedstock executed or - of . process 1 . 30 metals g close of μm) to MIM with plastic to 200 in and . the to to is is g a a 99 Powder Metallurgy (PM) for Beginners 6. 5. 4. 3. 2. 1. 3.6 for superalloys, the The medium AM process far AM process by (bionic AM process) AM today AM AM AdditiveManufacturing(AM, 3D Printing) is any requires achieves is some higher is . material . still THE structures), . speed size more powders other very limitations the components precious hot fine the and suited dynamic complexity net value . topic ( 5 ultimate which part - shape 60 metals for of are size (stainless in μm, or PM cannot single its design small and . … powder or depending progress technologies ) the the machining series be small freedom steels, higher better made cost, . . So on to 100 Powder Metallurgy (PM) for Beginners 4. 3. 2. 1. Contents 6. 5. 4. 3. 2. 1. KeyPM Processes and Applications A quickHistory ofPM Introduction:WhyPM? Conclusionsand Additive Manufacturing Additive Manufacturing (AM, 3D Printing) (MIM) Injection Molding Metal Hot Isostatic (Press Sinter) and Compaction Axial Process Sintering PowderProduction Pressing ( Pressing Outlook HIP ) 101 Powder Metallurgy (PM) for Beginners • • • Metals (RSM)SolidifiedRapidly goal. this achieve to process HIPgood very is a all consolidation steps. through microstructure fine very the maintain challenge is to The rates. high solidification very achieve can processes powder/particulate special PM Courtesy Powder Light Metals Light Powder Courtesy 102 Powder Metallurgy (PM) for Beginners Rapidly Solidified Metals: Melt SolidifiedProcessRapidlySpinning M m e a t a n l
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Courtesy Powder Light Metals Light Powder Courtesy M v a M c C u - a A t l i n g c u t t i n g 103 Powder Metallurgy (PM) for Beginners RS - AlSi CTEwithAlloys low RS Al - - X AlSi Cu - X Fe - X Ti - X e.g. Fe56 Fe56 Ni29 e.g. Co17 Courtesy Powder Light Metals Light Powder Courtesy 104 Powder Metallurgy (PM) for Beginners Solide Oxide FuelSolideOxide Cell 2012 2012 World PMCongress, Yokohama 105 Powder Metallurgy (PM) for Beginners M ulti - layer Filterlayer Elements(Semi AM CIP Process WPSProcess - Process) Courtesy GKN Courtesy Metals Sinter 106 Powder Metallurgy (PM) for Beginners Functional Materials? Functional EPMA the of Branch next The Tree: Functional Materials 107 Powder Metallurgy (PM) for Beginners Thank Youkind your for Attention! Powder Metallurgy Solutions Wuppertal, Germany Dr.Volker Arnhold 108