Powder Metallurgy Science, Technology, and Materials

Since the 1920s, modern powder metallurgy has been used to produce a wide range of structural powder metallurgy components, self-lubricating bearings, and cutting tools. The conventional method involves the production of metal powders and the manufacture of useful objects from such powders by die compaction and sintering. Powder injection molding permits the production of stronger, more uniform, and more complex powder metallurgy parts. A detailed discussion of powder metallurgy materials and products is given in this book. Worked examples, exercises, questions, and problems are included in each chapter.

Chapter 1. Introduction1.1 Powder Production and Characterisation1.2 Powder Treatment1.3 Powder Compaction1.4 Sintering1.5 Full Density Processing1.6 Secondary Treatments of P/M parts1.7 Applications1.8 Holistic View of P/M Science and TechnologyQuestions and ProblemsFurther ReadingsChapter 2. Powder Production2.1 Chemical Methods2.2 Electrolytic Method2.4 Evaporation Method2.5 Mechanical MethodQuestions and ProblemsFurther ReadingsChapter 3. Powder Characterisation3.1 Chemical Composition and Structure3.2 Particle Size and Shape3.3 Particle Surface Topography3.4 Surface Area3.5 Apparent and Tap Densities3.6 Flow Rate3.7 Compressibility3.8 Green Strength3.9 Pyrophorocity and Toxicity3.10 Powder Production Methods and Characteristics RelationsQuestions and Problems Further ReadingsChapter 4. Powder Treatment4.1 Annealing and Diffusion Alloying4.2 Powder Mixing / Milling4.3 Granulation4.4 Coating on Metal Powders4.5 Powder DegassingQuestions and ProblemsFurther ReadingsChapter 5. Powder Compaction5.1 Basic Aspects 5.2 Die Compaction5.3 Warm Compaction5.4 Wet Compaction5.5.Cold Isostatic Compaction5.6 Powder Roll Compaction5.7 Powder Extrusion5.8 Injection Moulding5.9 Green Part Materials HandlingQuestions and ProblemsFurther ReadingsChapter 6. Pressureless Powder Shaping6.1 Slip Casting / Slurry Moulding6.2 Tape Casting6.3 Electrophoretic Deposition6.4 Spray Deposition / Forming6.5 Solid Preform FabricationQuestions and ProblemsFurther ReadingsChapter 7. Sintering Theory7.1 Solid State Sintering7.2 Activated Solid State Sintering7.3 Liquid Phase Sintering7.4 Activated Liquid Phase SinteringQuestions and ProblemsFurther ReadingsChapter 8. Sintering Technology8.1 Debinding of Powder Compacts8.2 Loose Sintering8.3 Sintering Furnaces8.4 Sintering Zones8.5 Rapid Sintering Processes8.6 Sintering Atmosphere8.7 Sintering Atmosphere Analysis and Control8.8 Process Variables8.9 Materials Variables8.10 Dimensional Changes8.11 Microstructural Changes8.12 Infiltration8.13 Sintered Parts Materials HandlingQuestions and ProblemsFurther ReadingsChapter 9. Full Density Consolidation9.1 Dynamic Powder Compaction9.2 Hot Pressing9.3 Hot Isostatic Pressing9.4 Powder Hot Extrusion9.5 Powder Hot Forging9.6 Powder Preform Rolling9.7 Spark SinteringQuestions and ProblemsFurther ReadingsChapter 10. Secondary Treatments10.1 Sizing10.2 Machining10.3 Impregnation10.4 Surface Engineering10.5 Heat Treatment10.6 Joining Questions and ProblemsFurther ReadingsChapter 11. Testing and Quality Control of P/M Materials and Products11.1 Sampling11.2 Density11.3 Sintered Porosity and Pore Distribution11.4 Structure of Sintered Materials11.5 Differential Thermal Analysis11.6 Thermal Expansion11.7 Thermal Shock Resistance11.8 Thermal Conductivity11.9 Optical Properties11.10 Hardness11.11 Strength11.12 Impact Test11.13 Fracture Toughness11.14 Fatigue Behaviour11.15 Creep Behaviour11.16 Fracture Behaviour11.17 Wear Resistance11.18 Electrical Resistivity11.19 Magnetic Properties11.20 Corrosion Resistance11.21 Quality Control Aspects of P/M PartsQuestions and ProblemsFurther ReadingsChapter 12. Metallic and Ceramic P/M Materials12.1 Low Alloy Steels12.2 High Alloy Steels 12.3 Copper Alloys12.4 Aluminium Alloys12.5 Silver Alloys12.6 Nickel Alloys12.7 Titanium Alloys12.8 Refractory Metals and Alloys12.9 Intermetallics12.10 Ceramic Systems12.11 Cermets12.12 Ceramic –Ceramic CompositesQuestions and ProblemsFurther ReadingsChapter 13. P/M Applications13.1 Structural Applications13.2 Machine Tool Applications13.3 Power Generation Applications13.4 Filter Applications13.5 Friction Applications13.6 Electrical Applications13.7 Magnetic Applications13.8 Oxygen Sensor Applications13.9 Thermal Management Applications13.10 Bio-Implant ApplicationsQuestions and ProblemsFurther ReadingsChapter 14. Techno-economics of P/M Processing14.1 Costs of Metal and Ceramic Powders14.2 Economics of Metal Powder Production Methods14.3 Economic Aspects of Sintered Parts14.4 Energy Aspects of Sintering Process14.5 Economic Aspects of Full Density Consolidation14.6 Economic Aspects of Powder Injection Moulding14.7 Economic Aspects of Secondary Treatments14.8 Economic Aspects of OutsourcingQuestions and ProblemsFurther Readings

Dr Anish Upadhyaya, Associate Professor, Department of Materials Science and Engineering, IIT Kanpur, Kanpur, has been an advocate of powder metallurgical processing due to its high materials utilisation, near net-shaping and energy efficiency. He has done pioneering work in the area of microwave sintering of metallic systems and has been conferred several awards, including Metallurgist of the Year (2009) from Ministry of Steel, Government of India, and has has co-authored a book, Materials Science and Engineering.Dr GS Upadhyaya, Retired Professor, Department of Materials and Metallurgical Engineering, IIT Kanpur, Kanpur, has made significant contributions to sintering science and technology through his research. He has published more than 300 original papers and authored/edited 14 books on sintered materials. He has trained a large number of students in powder metallurgy, who are now working in academia, research and industry. He is a materials consultant based in Varanasi, India.