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

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

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

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

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

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

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

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

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