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    Particulate Materials Processing Lecture Notes

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    gtdombo
    This document provides an overview of particulate material processing. It discusses how particulate technology can be used to manufacture products from powdered metals and ceramics through compaction and sintering. This allows the production of components that may be difficult or inefficient to make through other methods, including porous materials and those with high melting points. Particulate processing offers advantages over casting and machining like reduced scrap and ability to achieve close tolerances. However, it also has limitations such as higher tooling costs and potential porosity variations within parts.

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    Particulate Materials Processing Lecture Notes

    Uploaded by

    gtdombo
    245 views14 pages
    This document provides an overview of particulate material processing. It discusses how particulate technology can be used to manufacture products from powdered metals and ceramics through compaction and sintering. This allows the production of components that may be difficult or inefficient to make through other methods, including porous materials and those with high melting points. Particulate processing offers advantages over casting and machining like reduced scrap and ability to achieve close tolerances. However, it also has limitations such as higher tooling costs and potential porosity variations within parts.

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    This document provides an overview of particulate material processing. It discusses how particulate technology can be used to manufacture products from powdered metals and ceramics through compaction and sintering. This allows the production of components that may be difficult or inefficient to make through other methods, including porous materials and those with high melting points. Particulate processing offers advantages over casting and machining like reduced scrap and ability to achieve close tolerances. However, it also has limitations such as higher tooling costs and potential porosity variations within parts.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    245 views14 pages

    Particulate Materials Processing Lecture Notes

    Uploaded by

    gtdombo
    This document provides an overview of particulate material processing. It discusses how particulate technology can be used to manufacture products from powdered metals and ceramics through compaction and sintering. This allows the production of components that may be difficult or inefficient to make through other methods, including porous materials and those with high melting points. Particulate processing offers advantages over casting and machining like reduced scrap and ability to achieve close tolerances. However, it also has limitations such as higher tooling costs and potential porosity variations within parts.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 14

    CHAPTER 1: OVERVIEW OF PARTICULATE

    MATERIAL PROCESSING
    • Traditionally, most manufacturing processes
    involve casting and or forming of engineering
    materials (metals, ceramics, polymers,
    composites etc)
    • Casting is most common manufacturing
    method which involves pouring of liquid
    material is poured into a die cavity of desired
    shape and held there to solidify
    • Time the hot metal is allowed time to solidify
    and the time depends on the size and shape of
    product.b
    • product is then finished by machining or polishing
    to required size.
    • While casting and forming processes (e.g. rolling,
    drawing, forging etc) offer various advantages
    related to lower costs, they have got their own
    limitations
    in the manufacturing of refractory materials
     porous products
    • particulate technology becomes handy
    1.1 Definitions
    • Particle technology: the art of the handling and
    processing of particles into useful products.
    • Particles can be bulk solids, particulate solids
    and granular solids; liquid drops (emulsions)
    and gas bubbles.
    • In particle technology for manufacturing
    purposes we are mainly concerned with solid
    particles that are used to manufacture metal
    and ceramic products
    • Powdered materials are important in various
    industries such as;
    Consolidated via compacting and sintering to give
    finished part or billet for further machining
    Used in paints vanishes, printing inks, welding
    electrodes etc
    Reagents in the chemical industry
    Explosives in military and mining applications
    • In this module we will only be concerned with
    the purpose highlighted in number 1
    • For metals and ceramics, the technology of
    producing products from powdered material is
    normally referred to as Powder Metallurgy (PM)
    • After manufacturing, the powders are then
    consolidation into useful products.
    • Consolidation is achieved through compacting
    and heating.
    • Sintering is the term used in PM for heating to
    consolidate: is performed at a temperature
    below melting point of the major constituents.
    • The size range of “particles” ranges from 10-9 to
    10-1m

    • In this module we are concerned with particles


    in the range 0.1 to 200µm
    1.2 Why Particulate Material Processing?
    • Some components may not be made (efficiently) by
    any other methods e.g. fabrications with heavy
    refractory metals; W, Mo, Os; Ta or ceramic materials,
    WC, Si3N4 etc that have got very high melting points,
    • For porous products (e.g. self-lubricating bearings)
    and magnetic cores
    • Engineering components that compete with those
    made by conventional casting, working and
    machining e.g. where large quantities of small parts
    (e.g gears) are required PM has the following
    advantages;
    Machining eliminated or reduced (yield 95% or
    higher) (Near-net)
    Scrap losses eliminated or reduced
    Close dimensional tolerances maintained
    Good surface finish
    Almost any combination of metals (or non-
    metals) can be achieved
    High volume production possible
    • It may be difficult to produce a component by
    any other means
    • It ensures adequate mechanical properties by
    elimination voids, inclusions etc in the product
    1.3 Typical PM products
    • Fabrication of implements from high melting
    point metals
    • Wear resistant parts
    • Porous materials
    • Products with special frictional, magnetic and
    electrical properties
    1.3.1 statistics
    • At present, nearly 70% of PM parts are used in
    the automotive industry (e.g., in bearing caps,
    connecting rods, etc.).
    • The current world-wide PM market is roughly
    constituted by 25% ceramics, 60% metals, and
    15% carbides (cutting tools, drill bits, etc.)
    1.4 Limitations of PM
    • Relatively high tooling cost,
    • high cost of powders
    • porosity variation within a part,
    • and limitations on part design (part must be
    ejectable from the die after compaction).

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