Powder Metal 101

[@REVNUMANEWBERN]

Worked in Quality Control 40+ years in a Lawn Mower MFG plant and we purchased PM parts, I was always fascinated in the process and inspecting them, never had the opportunity to actually see such an operation

[@learningthings4129]

Hi Numa, In PM gear parts ,tooth density and part overall density will be same ?

[@lukenewhouse601]

Yes

[@keyikush]

I have a Diploma in Mechanical Engineering. Working as a technician in machinery company for 6 years. This is the first time i found out about powder metal production

[@ci6516]

I’m a CS student , but a long time ago one of my first jobs was working in a powdered metal plant . From that moment I knew physical engineering wasn’t for me and I went to computers. .

[@ci6516]

All I remember was seeing fire shooting from walls and machines and thinking “this the type of job peolle lose limbs “

[@jacobrzeszewski6527]

This is well and truly one of those marvels of manufacturing. Taking the cost of a plastic injection molded part and strength of a machined part. And while not having the exact same properties of both, it is a well worthwhile compromise. If it could even really be called a compromise.

[@Ramonchen-wn7xj]

we are the manufacture of the powder forming machine in china welcome to your consults

[@JohnHWelch63]

The sintering process doesn't necessarily get the parts to specs. The need to go on a sizing press after or sometimes come off the sinter furnace and go through a temper furnace. Some parts are done at that point and some need further work such as lathing, grinding, electroplating.

[@ma61king]

I did wonder how dimensionally accurate those parts were, I was thinking this might be a good substitute for metal die casting. The splined gears they showed here here made me think they must be able to get stuff pretty close to perfect

[@JohnHWelch63]

@@ma61king I operate a sinter furnace. The tolerance varies depending on what the part is used for. We mostly make parts for automotive use, like gears and gerotors for fuel pumps. I can tweak my furnace to change the part size right down to a matter of micrometers by adjusting either temp or belt speed, but not every single part will be exact right down to the micrometer. They need to be worked further on a sizing press. At least where I work there is nothing we manufacture that doesn’t need further work after sintering.

[@ma61king]

@@JohnHWelch63 Interesting, does the sizing press operate while the parts are still hot enough to be in a plastic state?

[@JohnHWelch63]

@@ma61king They can go on the sizing press at any time from right off the furnace until days later when they are fully cooled. Doesn't matter. I've never seen them work them on the press right away though. After they come off the furnace the sizing press is usually working a couple of orders ahead of them, so they always end up sitting for a while before sizing. Granted, I'm talking about the parts we make. Other plants might make parts that require different processes, IDK.

[@LQ-C]

​@@JohnHWelch63 I worked in many powered metal plants including MPP that made this video and i would say the majority of the parts do not get sized, they are done off the furnace Or features machined that cannot be made in the Press. We had one part that had like a 1 inch hole and the total tolerance was like .001" without sizing. I thought that we were going to have trouble with that but it was no problem but the induction hardening kept cracking the sprocket teeth among other problems we had. Someone else asked about tolerances. The larger and more complex the part the more it moves and the looser the tolerances need to be without sizing or machining. Powder metal Parts can be made to near machine tolerances and surface finishes out of the Furnace or sizing. The biggest hindrance to using powder metal is the cost of the tools and the cost of material is higher. There can be a big learning curve sometimes to try and get your Tooling in your process right to make good parts. You usually need to be making a lot of something to make it worth it. The material properties like strength and fatigue of powder metal parts are not as good as more conventional methods but good enough in many cases in much better than alternatives like plastic or zinc.

[@paulsolfelt8452]

I used to do all that stuff from presses to part cindering to cnc machines, interesting times!

[@duane2243]

been there done that in Beaver Dam Wi !!! 30 years ago

[@nuclearrabbit1]

RTX announced yesterday they've discovered rare defects in their powdered metal production in their NEO geared turbofan Airbus 320 engines. They require advanced inspections, and it only affects engines already in the field. What type of rare defect could get past part acceptance and process control testing?

[@sadiporter2966]

a powder was in the powder mixture that wasn't supposed to be there.

[@nuclearrabbit1]

@sadiporter2966 Yeah, thanks for the response. My post is obviously outdated. Turns out this wasn't as rare as initially believed. Many inspections and a lot of downtime for most of these engines as combustion chambers are replaced. Huge issues for many airlines, as well as RTX and Pratt. Not sure how a foreign substance gets into a powdered metal formula. I bet there is an internal investigation that will never see the light of day.

[@kovko69]

Wouldn't this make herringbone gear production just as easy as any other gear type? Obviously, after taking into account the initial setup with the right molds, pressures, accounting for the different angles of the gear teeth, maybe even having to make it a two-stage press process, etc.

[@TerrenceLP]

So cool normal people don't even know.

[@mpp3808]

It is amazing that this technology that has been around for such a long time is really unknown to most. Thanks for the view!

[@rubenclark8017]

Normal people?

[@REVNUMANEWBERN]

@@rubenclark8017 😂😂

[@bill3880]

informative thank you.

[@mpp3808]

You are welcome and we are glad you enjoyed!

[@dadyeshey5105]

The video content is so excellent, congratulations

[@m.a.s3171]

How it's made powder metal

[@learningthings4129]

In PM gear ,tooth density and overall density will be same ? Can we maintain same density?

[@zionnegus8760]

Actually the PM tensile strength is stronger than traditional machine parts

[@evilgrin123]

Can hot Isostatic pressing be used to remove the porosity you mention?

[@canys24bb78]

it can just reduced the porosity. The thing is to stay below the mT.

[@learningthings4129]

@@canys24bb78 In PM gear parts ,tooth density and part overall density will be same or different?

[@prathmeshsawant5248]

I have an question about powder can we use also in metal 3d printing (Direct Laser Printing) or

[@mpp3808]

Powders used in powdered metallurgy typically have a larger particle size than those used in 3D printing.

[@prathmeshsawant5248]

@@mpp3808 thank you for response

[@REVNUMANEWBERN]

Do YOU do metal 3D printing?? I'm a individual that I may want to have some 3D metal parts done for a future idea

[@prathmeshsawant5248]

@@REVNUMANEWBERN no I'm student of mechanical engineering

[@JohnHWelch63]

@@REVNUMANEWBERN i.e. 3D printed hand guns? 🤣

[@NandKishor-yt6fh]

what is approx costing for complete setup

[@19wael96]

Costing humley skimlyala?

[@DanielSamaniego-of5xl]

You keep saying you are using different "atmospheres"... atmosphere is an oxymoron for gas doesn't form spheres gas takes the shape of its container... so what do you mean when you say you are using different atmospheres (sphere shaped gas)?

[@rajasharma372]

M interested

[@rickpaulos]

Not as strong IMO. I've had several sintered parts fail.

[@TurboVisBits]

just depends on what it's for.. there is a lot of use cases where stronger processes should be used. Automotive oil pump gears is a great example of something that should be better than PM..

[@tonyb1968]

Same here. Sintered Reluctor wheel in KIA engines grenade.

[@REVNUMANEWBERN]

DEPENDS, that's why engineering should have all the testing parameters covered BEFORE such goes into production, years ago I tested zillions of these type parts, and only had a few shipments fail due to density tests, & I think then engineering approved their use

[@Mechaniclyfe]

Awesome thanks

[@mpp3808]

Welcome 😊

[@joshtargo6834]

Why not just cast the parts traditionally? What's the advantage of using the powder metal process?

[@henrychan720]

Higher accuracy and smoother finish.

[@房艳雷]

@@henrychan720 I am a supplier of metal powder from China. If you are interested in purchasing metal powder, please contact me.My Email:[e-mail]

[@REVNUMANEWBERN]

@@房艳雷 TY

[@AmazingChinaToday]

Cheaper and faster.

[@sridharnaidu2092]

Sir, I want to do my PhD in titanium Alloy in powder mettulurgy .is it good decision, please suggest

[@Tex1680]

This is why the planetary gears on a transmission in these newer cars break all the friggin time!!!!! HOT Forged or nothing!!!!