Powder Metallurgy Process FAQs

Powder production refers to the process of creating fine metal or alloy powders that serve as the raw material for forming parts.

Common methods include gas atomization, water atomization, electrolysis, and reduction.

Blending is the process of mixing different metal powders with binders and lubricants to enhance powder fluidity, improve compressibility, and reduce demolding force.

Some common lubricants include Acrawax, zinc stearate, and lithium stearate.

In powder metallurgy, compacting is the process of applying high pressure to metal powder within a die to shape it into the desired form.

The pressed metal powder, known as “green compact”, is typically pressed by mechanical or hydraulic presses

Powder metallurgy sintering is a manufacturing process in which green compacts are heated to a temperature below their melting point in a controlled atmosphere.

The heat causes the metal particles to bond, reducing porosity and increasing density.

This fusion imparts structural integrity and enhances the material’s mechanical properties, resulting in a strong and durable final product…

Sizing in powder metallurgy is a secondary operation performed on sintered components to achieve tighter tolerances.

After sintering, powder metal parts may undergo slight dimensional changes due to shrinkage or distortion.

Sizing corrects these deviations by re-press the sintered part into the die.

Impregnation fills the tiny pores in sintered parts with oil or resin. Oil impregnation creates self-lubricating parts, while resin impregnation seals the surface for better strength, corrosion resistance, or plating.

Infiltration is a process where a low melting point metal, like copper, is drawn into the pores of a sintered part. This improves density, strength, toughness, of the parts.

Atomization produces metal powders by spraying molten metal with gas or water. Gas atomization creates nearly spherical, low-oxygen particles. Water atomization forms irregular powders with higher oxygen content.

Sintered parts gain additional features or improved mechanical properties and surface finish through secondary operations. Common secondary operations include:

• Machining.
• Sizing.
• Deburring.
• Copper infiltration.