powder metallurgy structural components: comparative

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Powder Metallurgy structural components:comparative overview vs othercompetitive technologies

Advanced Engineering 2017Birmingham (UK), 2nd-November-2017

Table of contentsTable of contents

4. Comparison of Powder Metallurgy to competitive technologies by case studies

1. Powder Metallurgy: manufacturing process and components

2. Why Powder Metallurgy for structural parts?

3. Limiting factors for Powder Metallurgy

5. PM self-lubricating bearings

The PM manufacturing processThe PM manufacturing process

Complementary operationsComplementary operations

PM structural componentsPM structural components

PM soft magnetic componentsPM soft magnetic components

Why PM for structural parts?Why PM for structural parts?Complex shapes High dimensional

accuracyReliability and repeat-ability in large series

Excellent surface finish

Unique and isotropic materialsSelf-lubrication

SAND MOULD CASTINGSAND MOULD CASTING

ISO IT TOLERANCE CLASS PROCESSESPROCESSES 7 8 9 10 11 12 13 14 15 16 17

INVESTMENT CASTINGINVESTMENT CASTING

HOT FORGING - EXTRUSION / DEEP DRAWINGHOT FORGING - EXTRUSION / DEEP DRAWING

COLD FORGING - EXTRUSIONCOLD FORGING - EXTRUSION

MACHININGMACHINING

FINE BLANKING / STAMPINGFINE BLANKING / STAMPING

POWDER METALLURGY (P/M)POWDER METALLURGY (P/M)

POWDER INJECTION MOULDINGPOWDER INJECTION MOULDING

Standard tolerance rangesReachable ranges in special cases

WARM FORGING - EXTRUSIONWARM FORGING - EXTRUSION

Dimensional accuracyDimensional accuracy

ROLLINGROLLING

Tooling costTooling cost

SAND MOULD CASTINGSAND MOULD CASTING

COST (x1,000) PROCESSESPROCESSES 1 2 5 10 20 50 100

INVESTMENT CASTINGINVESTMENT CASTING

HOT FORGINGHOT FORGING

EXTRUSIONEXTRUSION

MACHININGMACHINING

FINE BLANKING / STAMPINGFINE BLANKING / STAMPING

POWDER METALLURGY (P/M)POWDER METALLURGY (P/M)

POWDER INJECTION MOULDINGPOWDER INJECTION MOULDING

WARM FORGING – COLD FORGINGWARM FORGING – COLD FORGING

DEEP DRAWINGDEEP DRAWING

ROLLINGROLLING

SAND MOULD CASTINGSAND MOULD CASTING

PARTS (x1,000) PROCESSESPROCESSES 1 2 5 10 20 50 100 200 500

INVESTMENT CASTINGINVESTMENT CASTING

HOT FORGING - DEEP DRAWINGHOT FORGING - DEEP DRAWING

EXTRUSIONEXTRUSION

MACHININGMACHINING

FINE BLANKING / STAMPINGFINE BLANKING / STAMPING

POWDER METALLURGY (P/M)POWDER METALLURGY (P/M)

POWDER INJECTION MOULDINGPOWDER INJECTION MOULDING

Standard production runsSpecial production runs

WARM FORGING / COLD FORGINGWARM FORGING / COLD FORGING

Economic production runEconomic production run

ROLLINGROLLING

Limiting factor: SIZELimiting factor: SIZELimited by:

Compacting surface: Depends on powder compressibility and press size. Orientative data: Press size 1,200 Tm max.,

compacting surface 180 cm2 max., outer diameter 200 mm max.

Length: Limited by ejection forces, density gradient and press architecture. Orientative data: Length 80 mm max.

Raw material cost. Orientative data: Steel rod or sheet: 0.7-1.6 Eu/Kg,

PM steel: 1.1-2.8 Eu/Kg

Den

sity

Compacting pressure

WarmCold

Limiting factor: DENSITYLimiting factor: DENSITY

Limiting factor: FORMABILITYLimiting factor: FORMABILITY

The compacting processThe compacting process Die filling Compacting Ejection

Powderfilling

Robust tooling

Ejectability

Compactintegrity

Technologies comparisonTechnologies comparisonSand Casting

Powder Injection Moulding

Powder Metallurgy

Technologies comparisonTechnologies comparisonForging Powder Metallurgy

Machining Powder Metallurgy

Technologies comparisonTechnologies comparisonStamping Powder Metallurgy

Fine Blanking Powder Metallurgy

Extrusion

Technologies comparisonTechnologies comparisonDeep Drawing

Powder Metallurgy

Rolling

Powder Metallurgy Powder Metallurgy

PM self-lubricating bearingsPM self-lubricating bearings

Economy:- No need of additional lubrication- Maintenance-free

Reliability:- Elimination of seizure risk- Long life without wear

Performance:- Extremely silent- Low friction coefficient (up to 0.01)- High dimensional precision- Dynamic load up to 10 MPa- Linear speed up to 8 m/s (30,000 rpm)- Working temperature -60°C +230°C

Bearings comparisonBearings comparisonRotational PV limit (orientative data)

Linear speed (m/s)

PV (M

Pa·m

/s)

Hydrodynamic(with external lubrication)

Plastic

Ball bearing

Bimetallic

Sintered(bronze and iron)

THANK YOUTHANK YOUfor your valuable timefor your valuable time

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