Powders metal processing

Beryllium and aluminum are virtually insoluble in one another in the soHd state. The potential therefore exists for an aluminum—beryllium metal matrix composite with lower density and higher elastic modulus, ie, improved specific modulus, than conventional aluminum alloys produced by ingot or powder metal processing. At least one wrought composite system with nominally 62 wt % Be and 38 wt % A1 has seen limited use in aerospace appheations (see Composites). 

Figure 9.29. The powder metal process (a) pi ad rig powder in die (b) compacting powder to 90% density tc) sintering molding to full density at higher temperature.

Miscellaneous Methods. Powdered metals such as aluminum, chromium, nickel, and copper, along with various aHoys, can be appHed to parts by electrostatic deposition. The metal strip containing the attached powdered metal must be further processed by cold rolling and sintering to compact and bond the metal powder. 

R. M. German and R. G. lacocca, "Powder Metallurgy Processing and AppHcations for IntermetaUics," Mdvances in Powder Metallurgy (N Particulate Materials, Vol. 6, Metal Powder Industries federation, Princeton, N.J., 1993. 

PROCESS MATERIAL. IMPACT EXTRUSION COLD FORMING COLD EXTRUSION SHEET METALWORK MACHINING POWDER METAL SINTERING... 

There is a material to process compatibility risk for impact extrusion, cold forging, cold extmsion, sheet metalworking, machining and powder metal sintering processes because their respective process capability maps relate to the ideal material case. 

POWDER METAL SINTERING PROCESS CAPABILITY MAP (RADIAL TOLERANCES ONLY)... 

Pure iron, when needed, is produced on a relatively small scale by the reduction of the pure oxide or hydroxide with hydrogen, or by the carbonyl process in which iron is heated with carbon monoxide under pressure and the Fe(CO)5 so formed decomposed at 250°C to give the powdered metal. However, it is not in the pure state but in the form of an enormous variety of steels that iron finds its most widespread uses, the world s annual production being over 700 million tonnes. 

Methods are used to produce the more costly rapid prototypes include those that produce models within a few hours. They include photopolymerization, laser tooling, and their modifications. The laser sintering process uses powdered TP rather than chemically reactive liquid photopolymer used in stereolithography. Models are usually made from certain types of plastics. Also used in the different processes are metals (steel, hard alloys, copper-based alloys, and powdered metals). With powder metal molds, they can be used as inserts in a mold ready to produce prototype products. These systems enable having precise control over the process and constructing products with complex geometries. 

This process uses a moving laser beam, directed by a computer, to prepare the model. The model is made up of layers having thicknesses about 0.005-0.020 in. (0.012-0.50 mm) that are polymerized into a solid product. Advanced techniques also provides fast manufacturing of precision molds (152). An example is the MIT three-dimensional printing (3DP) in which a 3-D metal mold (die, etc.) is created layer by layer using powdered metal (300- or 400-series stainless steel, tool steel, bronze, nickel alloys, titanium, etc.). Each layer is inkjet-printed with a plastic binder. The print head generates and deposits micron-sized droplets of a proprietary water-based plastic that binds the powder together. 

Sintering is the process of forming a mechanical part from a powdered metal by fusing the particles together under pressure and heat. The temperature is maintained below the melting point of the basis metal. 

Sintering processes have been used since antiquity to alter the properties of ores and ore concentrates, powdered metals and alloys such as bloomery iron, ceramics, and glass. Bloomery iron, for example, was sintered in a forge, and the operation was often referred to as forge sintering. 

To protect steel piping and wire we can powder coat it with a layer of nylon 11. The powder coating process consists of immersing metal heated to above the melting point of nylon II (approximately 190 °C) in a fluidized bed of the polymer powder. When the polymer powder comes into contact with the heated metal, it melts and fuses to form a continuous coating. Powder coated products include hospital bed frames, shopping trolleys, and dishwasher racks. 

Droplet Formation in Gas Atomization. Experimental and modeling studiesl160 161 169] 318] 319] 321]- 325] have shown that gas atomization of liquid metals in spray forming and powder metallurgy processes may take place in two primary modes, i.e., liquid jet-ligament breakup and liquid film-sheet breakup. 

A typical lithium-ion cell consists of a positive electrode composed of a thin layer of powdered metal oxide (e.g., LiCo02) mounted on aluminum foil and a negative electrode formed from a thin layer of powdered graphite, or certain other carbons, mounted on a copper foil. The two electrodes are separated by a porous plastic film soaked typically in LiPFe dissolved in a mixture of organic solvents such as ethylene carbonate (EC), ethyl methyl carbonate (EMC), or diethyl carbonate (DEC). In the charge/ discharge process, lithium ions are inserted or extracted from the interstitial space between atomic layers within the active materials. 

Thermal reduction processes have been apphed successfully in making the metal from salts. In one such process, potassium fluotantalate is reduced with sodium metal at high temperatures to form tantalum powder of high purity and small particle size. Also, tantalum oxide can be reduced at high temperatures in vacuum with aluminum, silicon, or tantalum carbide. When the oxide is reduced by tantalum carbide, a metal sponge is obtained which can be embrittled with hydrogen to form powder metal. 

The powder-forming processes are similar in many ways to those nsed for powder metallurgy described in the previons section. For example, pressing is a common method for processing ceramics however, ceramic powders can be pressed in either dry or wet form. In wet form, they can also be extended, just like metals, and cast in a variety of process variations. The nominal forming pressures and shear rates associated with some of these processing methods are snmmarized in Table 7.3. Yon may want to refer back to this table when each of the varions processing techniques is described in more detail. 

The pentavalent halides are the most stable, but even these can be prepared only in the dry way because of the readiness with which they undergo hydrolysis. The trichloride is obtained by reduction of the pentachloride with a powdered metal (lead, aluminium, zinc) the same process has also given a dichloride and perhaps a tetrachloride, but their formation awaits independent confirmation. The preparation of the chloroadi, HTasCl7.4H20, is of interest in that corresponding... 

---