Mansura University

Student Name: Ahmed ELSaid Hassan Galala

‫احمد السعيد حسن احمد جالله‬
Section: 1
Submission Date:

Report .N ( 5 )

Grade: (Poor/Fair/Good/V.Good/Excellent)
Question 1) Discuss in details the basic principles of powder
metallurgy technology.

Question 2) With schematic drawing details clearly discuss the five

steps of powder metallurgy production process.

Question 3) What is the Atomization process; and accordingly explain

with sketches the Cyclonic separation system.

Question 4) Discuss the following processes:

• Powder Compaction,
• Cold compaction,
• Cold isostatic pressing and
• Hot isostatic pressing

Question 5) Discuss the following:

• General Sintering effective,
• Processes and advantages of solid state sintering and
• Ceramic sintering.

Question 6) In clear Points discuss the advantages of powder

metallurgy.

Question 7) Define what is the Atomization process, and then

explain with full sketches the following processes:
• Gas atomization and
• Water atomization.

Question 8) With clear diagram sketches explain the flow chart steps
of powder metallurgy procedure for engineering products
Question 1) Discuss in details the basic principles of powder
metallurgy technology.
Powder technology is the science for the manufacture of parts from
metal powders by compaction and heating that creates a homogeneous
mass. Heating is executed in a furnace and is called sintering. The
temperature at which sintering is performed is lower than the melting
point of the powdered material. Sintering consists of diffusion in solid
state by which particles of compacted powder are bonded together.
Question 2) With schematic drawing details clearly discuss the five
steps of powder metallurgy production process.

Powder manufacture (Atomization).

Powder mixing and blending.

compacting.

sintering.

Finishing.

1- Powder manufacture (Atomization);

Powders may be prepared by crushing, grinding,
chemical reactions, or electrolytic deposition. also
have been prepared by directing a stream of molten
metal through a high-temperature plasma jet or
flame, atomizing the material. Virtually all iron
powders are produced by one of two processes: the
sponge iron process or water atomization.

2-Powder mixing and blending;

The majority of powders are mixed with

other powders, binders, and lubricants to
achieve the desired characteristics in the
finished product. Sufficient diffusion must
occur during sintering to ensure a uniform
chemistry and structure. Unique
composites can be produced. Blending or
mixing operations can be done either wet or dry.
3-Compacting;
Loose powder is compacted and
densified into a shape, known as green
compact. Most compacting is done
with mechanical presses and rigid
tools. Hydraulic and pneumatic presses
are also used.

4-Sintering;
After compaction, powdered materials
are heated in a controlled atmosphere in
a process known as sintering. The
temperature at which sintering is
performed is lower than the melting
point of the powdered material. During
this process, the surfaces of the particles
are joined, and desirable properties are
achieved.

5-Finishing;
The application of finishing processes to the sintered
part. In the Powder Metallurgy industry, such
processes are often referred to as “secondary
operations”.
Question 3) What is the Atomization process; and accordingly
explain with sketches the Cyclonic separation system.

Atomization;
is accomplished by forcing a molten metal stream through an orifice
at moderate pressures. A gas is introduced into the metal stream
just before it leaves the nozzle, serving to create turbulence as the
entrained gas expands (due to heating) and exits into a large
collection volume exterior to the orifice. The collection volume is
filled with gas to promote further turbulence of the molten metal
jet. Air and powder streams are segregated using gravity or cyclonic
separation.

Cyclonic separation;
is a method of removing particulates from an air, gas or liquid
stream, without the use of filters. Rotational effects and
gravity are used to separate mixtures of solids and fluids. high
speed rotating air is established within a cylindrical container
called a cyclone. Air flows in a helical pattern, beginning at the
top of the cyclone and ending at the bottom end before
exiting the cyclone in a straight stream through the center of
the cyclone and out the top. Larger particles in the rotating
stream have too much inertia to follow the tight curve of the
stream, and thus strike the outside wall, then fall to the
bottom of the cyclone where they can be removed.
Question 4) Discuss the following processes:
• Powder Compaction,
• Cold compaction,
• Cold isostatic pressing and
• Hot isostatic pressing

1- Powder Compaction:
Powder compaction, known as powder pressing, is the process of compacting
metal powder in a die through the application of high pressures. Typically the
tools are held in the vertical orientation with the punch tool forming the bottom
of the cavity. The powder is then compacted into a shape and then ejected from
the die cavity. In a number of these applications the parts may require very little
additional work for their intended use; making for very cost efficient
manufacturing.

2- Cold compaction:
Cold compressing is the most important compaction method in powder
metallurgy. It starts from bulk powders containing very small amounts and
sometimes even no lubricant or binder additions.

3- Cold isostatic pressing:

Cold isostatic pressing uses fluid as a means of applying pressure to the mold at
room temperature. after removal the part still needs to be sintered. And the
process of sintering is usually conducting at atmospheric pressure. Optional
secondary processing often follows to obtain special properties.

4- Hot isostatic pressing:

in Hot isostatic pressing the compaction and sintering of the part occur
simultaneously by applying heat ranging from 480°C to1230°C. Argon gas is the
most common gas used because it is an inert gas, thus prevents chemical
reactions during the operation.
Question 5) Discuss the following:
• General Sintering effective,
• Processes and advantages of solid state sintering and
• Ceramic sintering.

1-General sintering effective;

Sintering is effective when the process reduces the porosity and enhances
properties such as strength, electrical conductivity, translucency and thermal
conductivity; yet, in other cases, it may be useful to increase its strength but keep
its gas absorbency constant as in filters or catalysts. During the firing process,
atomic diffusion drives powder surface elimination in different stages, starting
from the formation of necks between powders to final elimination of small pores
at the end of the process.

2-Processes and advantages of solid state sintering;

Solid state sintering is the process of taking metal in the form of a powder and
placing it into a mold or die. Once compacted into the mold the material is
placed under a high heat for a long period of time. Under heat, bonding takes
place between the porous aggregate particles and once cooled the powder has
bonded to form a solid piece.

3-Ceramic sintering;
Sintering is part of the firing process used in the manufacture of pottery and
other ceramic objects. Some ceramic raw materials have a lower affinity for
water and a lower plasticity index than clay, requiring organic additives in the
stages before sintering. The general procedure of creating ceramic objects via
sintering of powders includes: -Mixing water, binder, deflocculates, and unfired
ceramic powder to form a slurry. -Spray-drying the slurry. -Putting the spray
dried powder into a mold and pressing it to form a green body (an unsintered
ceramic item). -Heating the green body at low temperature to burn off the
binder. -Sintering at a high temperature to fuse the ceramic particles together.
Question 6) In clear Points discuss the advantages of powder
metallurgy.

Production of components via powder metallurgy has many potential advantages

when compared to producing them via conventional methods, such as machining
frm billets. Some of these advantages include:

1- Huge potential savings in production by using powder metallurgy which is

geared towards mass production.
2- The flexibility to produce compositions not possible by other methods e.g.
metals and non-metals, as well as metal-metal combinations.
3- Powder metallurgy is a near nett shape forming process, meaning that in many
cases no finishing operations are requited. Further the dimensional accuracy
possible is quite high.
4- Raw materials easily obtainable and relatively inexpensive.
5- Repeatability across parts is normal meaning consistent properties and
dimensions for components.
6- The number of operations required to produce a finished part is often less than
other fabrication methodologies.
7- Parts can be manufactured with controlled porosity. Further, it is possible to
infiltrate these pores either with other materials e.g. lower melting point metals or
lubricants.
8- The process generates very little scrap.
9- Potentially very high production rates, especially compared to machining.
10- Parts can be manufactured with excellent wear resistant properties and
friction co-efficients
11- Parts have sound and vibration damping properties.
12- Powder metallurgy can produce geometries not possible by processes such as
machining
13- Parts have good chemical homogeneity.
14- Powder metallurgy can also be used for fabrication of magnetic components,
as well as controlling magnetic properties to some degree.
15- The time taken to take a part from concept to production using powder
metallurgy is often quite short which has economic benefits.
Question 7) Define what is the Atomization process, and then
explain with full sketches the following processes:
• Gas atomization and
• Water atomization.
Atomization process:

Atomization is the process of converting an analyte in solid, liquid or solution

form to a free gaseous atom. It is the transformation of a bulk liquid into a
spray of liquid droplets in a surrounding gas or vacuum.
The range of metals that can be atomized extends to all metals that are
capable of being melted industrially.
Atomization is accomplished by forcing a molten metal stream through an
orifice at moderate pressures. A gas is introduced into the metal stream just
before it leaves the nozzle, serving to create turbulence as the entrained gas
expands (due to heating) and exits into a large collection volume exterior to
the orifice. The collection volume is filled with gas to promote further
turbulence of the molten metal jet. Air and powder streams are segregated
using gravity or cyclonic separation. Most atomized powders are annealed,
which helps reduce the oxide and carbon content. The water atomized
particles are smaller, cleaner, and nonporous and have a greater breadth of
size, which allows better compacting. The particles produced through this
method are normally of spherical or pear shape. Usually, they also carry a
layer of oxide over them.
** Gas atomization:
1- Molten metal stream is dis-
integrated by means of high
velocity gas in this method .
2- The gases used are Ar , N2
,He gas jets .
3- The atomized powder are
collected in water bath .
4- Fluidized bed cooling is
used when certain
characteristics of powder are
desirable for example,
spherical shape or particles
with little or no oxide(surface)
content .
5- This process is costier than
water atomization .

** Water atomization:
1- This method uses high pressure water
jets to dis-integrate the molten metal
stream .
2- Water is used due to their higher
viscosity and superior quenching ability .
3- The process is in-expensive and can be
used both for small and large scale
production .
4- Metals and alloys which do not react
chemically with water cant be atomized
by this process .
Question 8) With clear diagram sketches explain the flow chart steps
of powder metallurgy procedure for engineering products.