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Powder Metallurgy structural components:comparative overview vs othercompetitive technologies
Advanced Engineering 2017Birmingham (UK), 2nd-November-2017
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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
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The PM manufacturing processThe PM manufacturing process
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Complementary operationsComplementary operations
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PM structural componentsPM structural components
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PM soft magnetic componentsPM soft magnetic components
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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
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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
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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
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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
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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
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Limiting factor: DENSITYLimiting factor: DENSITY
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Limiting factor: FORMABILITYLimiting factor: FORMABILITY
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The compacting processThe compacting process Die filling Compacting Ejection
Powderfilling
Robust tooling
Ejectability
Compactintegrity
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Technologies comparisonTechnologies comparisonSand Casting
Powder Injection Moulding
Powder Metallurgy
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Technologies comparisonTechnologies comparisonForging Powder Metallurgy
Machining Powder Metallurgy
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Technologies comparisonTechnologies comparisonStamping Powder Metallurgy
Fine Blanking Powder Metallurgy
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Extrusion
Technologies comparisonTechnologies comparisonDeep Drawing
Powder Metallurgy
Rolling
Powder Metallurgy Powder Metallurgy
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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
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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)
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