CHAPTER 7 FINISHING OPERATIONS ME596: Powder-based Manufacturing 7.1

CHAPTER 7 FINISHING OPERATIONS ME596: Powder-based Manufacturing 7.1

CHAPTER 7 FINISHING OPERATIONS ME596: Powder-based Manufacturing 7.1 Secondary and Finishing operations Coining (REPRESSING): increase in density r.t. strength increase work hardening. dimensional/shape change.

Sizing - impart dimensional accuracy to sintered part. Machining - Side holes, slots/grooves , no liquid coolant Grinding for improved dimensional accuracy and surface finish Cold/hot forging - <5% porosity superior properties ME596: Powder-based Manufacturing 7.2

Infiltration - pore free parts (iron based compacts with copper, lead infiltration wear applications) Oil impregnation lubrication, corrosion resistance Plating for wear resistance, improved appearance, and corrosion resistance. Heat treating ME596: Powder-based Manufacturing

7.3 Design Considerations ME596: Powder-based Manufacturing 7.4 Economics of Powder Metallurgy ME596: Powder-based Manufacturing

7.5 Advantage and Disadvantages of Powder Metallurgy Advantages Availability of a wide range of composites to obtain special mechanical and physical properties, such as stiffness, damping characteristics, hardness, density, toughness, and electrical and magnetic properties. Some of the highly alloyed new superalloys can be manufactures into parts by P/M processing. A technique for making parts from high-melting-point refractory metals, which

would be difficult or uneconomical to make by other methods. High production rates on relatively complex parts, with automated equipment requiring little labor. Good dimensional control and, in many instances, elimination of machining and finishing operations, thus eliminating scrap and waste and saving energy. Capability for impregnation and infiltration for special applications. ME596: Powder-based Manufacturing 7.6 Advantage and Disadvantages of

Powder Metallurgy Disadvantages Size of parts, complexity of shape of parts, and press capacity. High cost of powder metals compared to other raw materials. High cost of tooling and equipment for small production runs Mechanical properties, such as strength and ductility, that are generally lower those obtained by forging. However, the properties of fully-dense P/M parts made by HIP or additional forging can be better than those made by other processes. ME596: Powder-based Manufacturing

7.7 TRENDS ME596: Powder-based Manufacturing 7.8 SUMMARY ME596: Powder-based Manufacturing

7.9

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