[PDF] Advances in powder metallurgy : Properties processing and

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© Woodhead Publishing Limited, 2013

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xi Woodhead Publishing Series in Metals and Surface Engineering xv

Part I

Forming and shaping of metal powders 1

1 Advances in atomisation techniques for the

formation of metal powders 3

J. DU N K L E Y, atomising Systems limited, uk

1.1 Introduction 3

1.2 atomisation techniques 5

1.3 Problems and advances in gas atomisation 9

1.4 Problems and advances in water atomisation 14

1.5 Centrifugal atomisation 15

1.6 other atomisation techniques 17

1.7 Conclusion 17

1.8 references 17

2

Forming metal powders by electrolysis 19

G.Z. CH E N, university of nottingham, uk

2.1 background of electrometallurgy and powder

metallurgy 19

2.2 Principle and main technological prospects for the FFC Cambridge process 22

2.3 Production of metal powders by the FFC Cambridge process 26

2.4 Direct route from oxide precursors to alloyed powders 33

2.5 Conclusions and future trends 38

2.6 acknowledgement 39

2.7 references 39

Contents

© Woodhead Publishing Limited, 2013

viContents 3

Mechanochemical synthesis of nanocrystalline

metal powders 42
C. Su r y a n a r a y a n a, University of Central Florida, USA, and e. I v a n o v, Tosoh SMD, Inc., USA

3.1 Introduction 42

3.2 Mechanochemical processing 43

3.3 The process 47

3.4 Grain size and process variables 54

3.5 Displacement reactions 58

3.6 Consolidation 61

3.7 Powder contamination 62

3.8 Conclusions 65

3.9 References 66

4

Plasma synthesis of metal nanopowders 69

I. Ch a nG, University of Birmingham, UK

4.1 Introduction 69

4.3 Electrical arc discharge synthesis of metal nanopowders 70

4.4 Conclusions 82

4.5 References 83

5

Warm compaction of metallic powders 86

a. SImChI and A.A. noJo o mI, Sharif University of Technology, Iran

5.1 Introduction 86

5.2 Warm compaction process 90

5.3 Properties of warm compacted parts 98

5.4 Materials and applications 100

5.5 Future trends and concluding remarks 105

5.6 References 105

6 Developments in metal injection moulding (MIM) 109

I. ToD D and a.T. SI Da m b e

6.1 Introduction to metal injection moulding 109

6.2 Powders for metal injection moulding 111

6.3 Binders for metal injection moulding 115

6.4 Mixing and feedstock analysis 118

6.5 Injection moulding 122

6.6 Binder removal (debinding) 126

6.7 Sintering 133

6.8 Post-sintering 135

6.9 Applications and design 138

6.10 Conclusion 144

6.11 References 144

© Woodhead Publishing Limited, 2013

viiContents

Part II

Materials and properties 147

7

Advanced powder metallurgy steel alloys 149

h. Da n nInGe r and C. GIe r l-ma y e r, Vienna University of

Technology, Austria

7.1 Introduction 149

7.2 Composition of advanced pressed and sintered steel

components 151

7.3 Manufacturing routes for sintered steel components 155

7.4 Properties, microstructures and typical products 173

7.5 Powder injection moulded steel components 186

7.6 Powder metallurgy tool steels 190

7.7 Trends in ferrous powder metallurgy 195

7.8 Acknowledgements 196

7.9 Further reading 196

7.10 References 198

8

Powder metallurgy of titanium alloys 202

F. h. Fr o eS, Consultant, USA

8.1 Introduction 202

8.2 Powders 204

8.3 Near net shapes 209

8.4 Additive layer manufacturing and powder injection molding 222

8.5 Spraying and research-based processes 231

8.6 Future trends 236

8.7 Acknowledgements 238

8.8 References 239

9

Metal-based composite powders 241

n. ll o rCa-ISe r n and C. arT IeDa-GuZm á n, Universitat de

Barcelona, Spain

9.1 Introduction 241

9.2 Metal-based composite powder production 243

9.3 Copper- and aluminium-based composite powder systems 248

9.4 Other metal-based composite powders 257

9.5 Applications 262

9.6 Future trends 263

9.7 References 264

10

Porous metals: foams and sponges 273

r. Go oDa l l

10.1 Introduction 273

© Woodhead Publishing Limited, 2013

viiiContents

10.2 Powder processing: partial sintering and space holders 276

10.3 Powder processing: gas entrapment and additive layer

manufacturing 284

10.4 Properties of porous metals 288

10.5 Prediction of porous metal properties 294

10.6 Future perspectives 298

10.7 References 299

11

Evolution of microstructure in ferrous and non-

ferrous materials 308 h. Da n nInGe r, C. GIe r l-ma y e r and S. STr o b l, Vienna University of Technology, Austria

11.1 Introduction 308

11.2 Metallographic preparation techniques for powder

metallurgy products 309

11.3 Microstructures of ferrous powder metallurgy materials 319

11.4 Non-ferrous materials 339

11.5 Trends in microstructures of powder metallurgy products 352

11.6 Acknowledgements 354

11.7 Further reading 354

11.8 References 355

Part III

Manufacturing and densification of powder

metallurgy components 359
12

Microwave sintering of metal powders 361

D. aGr a w a l, Pennsylvania State University, USA

12.1 Introduction and background 361

12.2 Sintering of metallic powders 364

12.3 Bulk metal processing 369

12.4 Microwave-metal interaction: mechanism(s) 373

12.5 Future trends 375

12.6 Further reading 376

12.7 References 377

13 Joining processes for powder metallurgy

parts 380

C. Se lCu k, Brunel Innovation Centre, UK

13.1 Introduction 380

13.2 Welding processes for powder metallurgy parts 382

13.3 Other joining processes for powder metallurgy parts 390

13.4 Discussion 393

© Woodhead Publishing Limited, 2013

ixContents

13.5 Conclusions 396

13.6 References 397

14

Process optimization in component

manufacturing 399
G.m. Le e, Pusan National University, South Korea, and S.J. Pa r k, Pohang University of Science and Technology, South Korea

14.1 Introduction 399

14.2 Formal optimization 400

14.3 Optimization in the die compaction process 401

14.4 Powder injection moulding optimization 406

14.5 Sintering optimization 416

14.6 Design optimization of steady-state conduction 423

14.7 Conclusions 432

14.8 References 433

15

Non-destructive evaluation of powder metallurgy

parts 437

C. Se lCu k, Brunel Innovation Centre, UK

15.1 Introduction 437

15.2 Need and incentive for NDT 438

15.3 Problem/approach concept 441

15.4 Quality control by digital radiographic (DR) inspection in production 443

15.5 Challenges in relation to the state-of-the-art 444

15.6 Real-time on-line powder metallurgy parts inspection 449

15.7 Prior art in relation to radiography of particulate matter and near net-shape parts 451

15.8 Summary 452

15.9 References 454

16 Fatigue and fracture of powder metallurgy steels 455 n. Ch a w l a and J.J. wIl lIa mS, Arizona State University, USA

16.1 Introduction 455

16.2 Fracture behavior 458

16.3 Fatigue behavior 464

16.4 Residual stress effects on fatigue 473

16.5 Constitutive behavior of microstructural constituents 477

16.6 Summary 487

16.7 Acknowledgments 487

16.8 References 487

© Woodhead Publishing Limited, 2013

xContents

Part IV

Applications 491

17 Automotive applications of powder metallurgy 493 P. ra m a k rI Sh n a n, Indian Institute of Technology Bombay, India

17.1 Introduction 493

17.2 Powder metallurgy parts 494

17.3 Materials 505

17.4 Innovative powder metallurgy products 508

17.5 Emerging trends 511

17.6 Conclusions 517

17.7 References 517

18 Applications of powder metallurgy in biomaterials 520 m. br a m, Institute of Energy and Climate Research, Germany, T. e b e l and m. wo lF F, Institute of Materials Research, Germany, a . P. C ySn e ba r b oSa, Universidade Federal do Rio Grande do

Norte, Brazil and n. T

u nCe r, Anadolu University, Turkey

18.1 Introduction 520

18.2 Challenges of powder metallurgy biomaterials 521

18.3 Production of powder metallurgy biomaterials 526

alloy biomaterials 533
biomaterials 538

18.6 Case studies 543

18.7 Conclusions and future trends 547

18.8 Further reading 549

18.9 References 549

19 Applications of powder metallurgy to cutting tools 555 J. ko nS Ta nTy, AGH University of Science and Technology, Poland

19.1 Introduction 555

19.2 Tool design and composition 557

19.3 Diamond tool fabrication 568

19.4 Application of powder metallurgy diamond tools 574

19.5 Latest trends and developments 581

19.6 References 584

Index 587

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