MTE 449 Powder Metallurgy

Chapter 3 Applications of Powder Fabrication Technologies

Nagy El-Kaddah

Applications of Powder Fabrication Technologies

Materials Alloy steels (e.g. tool steel) Alumina Aluminum Beryllium Cemented carbide (WC-Co) Cobalt Composites (e.g. Al-SiC) Copper Copper alloys (e.g. brass) Gold Intermetallics (e.g. NiAl) milling air atomization, gas atomization, milling milling, gas atomization milling, attritor milling oxide reduction, chemical precipitation mechanical alloying, plasma atomization electrolytic, water atomization, gas atomization, chemical precipitation, oxide reduction, salt decomposition water atomization, air atomization electrolytic, air atomization, chemical precipitation gas atomization, reactive synthesis, centrifugal atomization Common Methods water atomization, gas atomization, centrifugal atomization

Applications of Powder Fabrication Technologies (cont.)

Materials Iron Nickel alloys Nickel Precious metals (Ag) Reactive metals (Ti) Refractory metals (W) Special alloys (Co-Cr) Superalloys Uranium Common Methods oxide reduction, water atomization, electrolytic, carbonyl decomposition, gas atomization, centrifugal atomization inert gas atomization, water atomization, centrifugal atomization carbonyl decomposition, electrolytic deposition, water atomization air atomization, electrolytic deposition, chemical precipitation chloride reduction, centrifugal atomization, chemical precipitation, hydride-dehydride oxide reduction, chemical precipitation, centrifugal atomization, plasma atomization gas atomization, water atomization, centrifugal atomization, plasma atomization gas atomization, centrifugal atomization, mechanical alloying oxide reduction, hydride-dehydride

Characteristics of Fabricated Metal Powders

Powder Al Al alloy Ag Au brass bronze Co alloy Cu Cu Fe Fe Fe Fe Fe Hf Process gas atomized air atomized milled air atomized water atomized air atomized gas atomized water atomized electrolytic water atomized gas atomized carbonyl oxide reduced centrifugal milled Shape spherical rounded flake spherical irregular spherical spherical nodular dendritic irregular spherical spherical porous spherical angular D50, m 30 65 10 130 38 125 90 62 40 75 66 5 50 75 9 O2, ppm 6000 11000 100 50 800 700 400 3300 1700 1100 1500 3800 10000 1000 1200 Apparent density, g/cm3 1.3 0.9 1.5 7.8 2.7 5.0 4.3 2.3 2.8 2.9 4.5 2.7 1.9 4.7 4.2 Tap density, g/cm3 1.4 1.4 11.9 3.3 5.4 5.2 3.4 3.6 3.4 5.0 4.3 3.0 5.0 6.5 Flow time, s nf nf 35 48 29 26 9 nf 35 14 nf

Characteristics of Fabricated Metal Powders (cont.)

Powder Mo Nb Ni Ni Ni3Al Pb Sn stainless stainless Ta Ti TiAl Ti alloy tool steel WC-Co W Process oxide reduced hydride milled hydromet carbonyl reactive water atomized air atomized gas atomized water atomized hydride milled chloride gas atomized centrifugal water atomized attritor milled oxide reduced Shape angular angular spherical spiky rounded ligamental ligamental spherical irregular angular sponge spherical spherical nodular angular polygonal D50, m 6 10 1 5 14 42 18 12 60 9 75 180 175 70 0.7 3 O2, ppm 1200 3800 4000 1500 2000 3000 7000 1000 2000 1700 1500 800 1300 1000 800 640 Apparent density, g/cm3 2.0 0.9 1.3 2.5 3.1 5.2 3.3 3.8 2.6 3.7 2.0 2.2 2.6 1.8 2.5 3.4 Tap density, g/cm3 3.1 1.0 2.6 3.3 3.8 4.7 3.7 5.8 2.5 2.4 2.9 2.4 4.3 6.7 Flow time, s nf nf nf nf nf 24 nf 38 30 50 nf 30 28 50 nf nf

Production Costs
Fabrication Route carbonyl decomposition centrifugal atomization electrolytic deposition gas atomization hydrothermal mechanical alloying milling oxide reduction plasma atomization reaction synthesis sol-gel precipitation vapor condensation water atomization Cost range, $/kg 7 10 4 20 6 10 3 -18 6 25 10 40 2 12 12 6 40 2 12 10 80 100 1000 1-2

Cost of Powder Materials

Price of commonly used materials, pegged to iron =1