Powder Metallurgy is the process of forming parts from various metallic powders. The process limits or eliminates much of the wastage associated with batch forging and cutting, as the metal powder is simply pressed into the desired shape and then sintered. This sintering step causes all the particles to adhere together, even if they are of different metal alloys.
The process begins with metal powder, often consisting of metal alloys mixed together in a way that will provide the desired properties. The metal powder can be processed into nearly any desired shape, such as a gear, by pressing it through a die that is die-casted with the desired shape.
Multiple kinds of pressing techniques and machines can be used, such as isostatic pressing and injection molding. Depending on the shape and complexity of the part, additional secondary operations may be needed. Various other processes such as deburring or grinding, can be used in order to achieve the desired finished product.
Then the part is sintered, which causes the metal powder particles to adhere to each other, forming one cohesive mass. The sintering also causes the desired properties to change and in most cases, increase due to the fact that porosity is reduced.
During the sintering process, additional elements can be added as well, such as lubricants and sintering aids, to improve the mechanical properties of the sintered part. After sintering, the part can be heat-treated or cold-worked depending on the material.
The process is used in various industries that require precision and complex shapes that batch forging and cutting cannot create. To make large parts, the powder metallurgy process is commonly used because the large part can be broken down into several smaller parts that can then be sintered and formed together.
The process is also being explored for use in the automotive and aerospace industries due to the high strength and lightweight characteristics that come with the powder metallurgy process. This process of forming parts from different metal powders is an important part of many manufacturing processes. It saves time and money, and allows for complex and intricate shapes. The process known as powder metallurgy is here to stay.
