Advances in powder metallurgy: Properties, processing and applications

617 Pages·2013·47.563 MB·English

by  Isaac Chang, Yuyuan Zhao

Advances in powder metallurgy
© Woodhead Publishing Limited, 2013
Related titles:
High-energy ball milling: mechanochemical processing of nanopowders
(ISBN 978-1-84569-531-6)
Sintering of advanced materials
(ISBN 978-1-84569-562-0)
Fundamentals of metallurgy
(ISBN 978-1-85573-927-7)
Details of these books and a complete list of titles from Woodhead Publishing can be
obtained by:
∑ visiting our web site at www.woodheadpublishing.com
∑ contacting Customer Services (e-mail: [email protected];
fax: [phone]; tel.: [phone] ext. 130; address: Woodhead
Publishing Limited, 80, High Street, Sawston, Cambridge CB22 3HJ, UK)
∑ in North America, contacting our US office (e-mail: usmarketing@woodheadpublishing.
com; tel.: [phone]; address: Woodhead Publishing, 1518 Walnut Street, Suite
1100, Philadelphia, PA 19102-3406, USA
If you would like e-versions of our content, please visit our online platform: www.
woodheadpublishingonline.com. Please recommend it to your librarian so that everyone in
your institution can benefit from the wealth of content on the site.
We are always happy to receive suggestions for new books from potential editors. To
enquire about contributing to our Materials series, please send your name, contact address
and details of the topic/s you are interested in to [email protected].
We look forward to hearing from you.
The team responsible for publishing this book:
Commissioning Editor: Nell Holden
Publications Coordinator: Emily Cole
Project Editor: Diana Paulding
Editorial and Production Manager: Mary Campbell
Production Editor: Richard Fairclough
Copyeditor: Marilyn Grant
Proofreader: Tony Phillips
Cover Designer: Terry Callanan
© Woodhead Publishing Limited, 2013
Woodhead Publishing Series in Metals and Surface
Engineering: Number 60
Advances in
powder metallurgy
Properties, processing and
applications
Edited by
Isaac Chang and Yuyuan Zhao
Oxford Cambridge Philadelphia New Delhi
© Woodhead Publishing Limited, 2013
Published by Woodhead Publishing Limited,
80 High Street, Sawston, Cambridge CB22 3HJ, UK
www.woodheadpublishing.com
www.woodheadpublishingonline.com
Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia,
PA 19102-3406, USA
Woodhead Publishing India Private Limited, 303, Vardaan House, 7/28 Ansari Road,
Daryaganj, New Delhi – 110002, India
www.woodheadpublishingindia.com
First published 2013, Woodhead Publishing Limited
© Woodhead Publishing Limited, 2013. Note: the publisher has made every effort to ensure
that permission for copyright material has been obtained by authors wishing to use such
material. The authors and the publisher will be glad to hear from any copyright holder it
has not been possible to contact.
The authors have asserted their moral rights.
This book contains information obtained from authentic and highly regarded sources.
Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts
have been made to publish reliable data and information, but the authors and the publisher
cannot assume responsibility for the validity of all materials. Neither the authors nor the
publisher, nor anyone else associated with this publication, shall be liable for any loss,
damage or liability directly or indirectly caused or alleged to be caused by this book.
Neither this book nor any part may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying, microfilming and recording, or by
any information storage or retrieval system, without permission in writing from Woodhead
Publishing Limited.
The consent of Woodhead Publishing Limited does not extend to copying for general
distribution, for promotion, for creating new works, or for resale. Specific permission must
be obtained in writing from Woodhead Publishing Limited for such copying.
Trademark notice: Product or corporate names may be trademarks or registered trademarks,
and are used only for identification and explanation, without intent to infringe.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Control Number: 2013939414
ISBN 978-0-85709-420-9 (print)
ISBN 978-0-85709-890-0 (online)
ISSN 2052-5559 Woodhead Publishing Series in Metals and Surface Engineering (print)
ISSN 2052-5567 Woodhead Publishing Series in Metals and Surface Engineering (online)
The publisher’s policy is to use permanent paper from mills that operate a sustainable
forestry policy, and which has been manufactured from pulp which is processed using
acid-free and elemental chlorine-free practices. Furthermore, the publisher ensures that the
text paper and cover board used have met acceptable environmental accreditation standards.
Cover photo courtesy of MIBA Sinter Austria GmbH, A-4655 Vorchdorf, Austria
Typeset by Replika Press Pvt Ltd, India
Printed by Lightning Source
© Woodhead Publishing Limited, 2013
Contents
Contributor contact details 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. Dunkley, 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. Chen, 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
© Woodhead Publishing Limited, 2013
vi Contents
3 Mechanochemical synthesis of nanocrystalline
metal powders 42
C. Suryanarayana, University of Central Florida, USA, and e.
Ivanov, 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. ChanG, University of Birmingham, UK
4.1 Introduction 69
4.2 Potential benefits and applications of metal nanopowders 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. noJoomI, 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. ToDD and a.T. SIDambe, University of Sheffield, UK
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
Contents vii
Part II Materials and properties 147
7 Advanced powder metallurgy steel alloys 149
h. DannInGer and C. GIerl-mayer, 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. FroeS, 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. llorCa-ISern and C. arTIeDa-GuZmán, 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. GooDall, The University of Sheffield, UK
10.1 Introduction 273
© Woodhead Publishing Limited, 2013
viii Contents
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. DannInGer, C. GIerl-mayer and S. STrobl, 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. aGrawal, 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. SelCuk, 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
Contents ix
13.5 Conclusions 396
13.6 References 397
14 Process optimization in component
manufacturing 399
G.m. Lee, Pusan National University, South Korea, and S.J. Park,
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. SelCuk, 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. Chawla and J.J. wIllIamS, 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