Sintered metal parts are made through a process that involves three main operations: powder mixing, compacting, and sintering. The raw material is a metallic powder, which can be pure metal or an alloy, and is chosen based on the desired characteristics of the final component. The process aims to create a strong, integral part from the powdered metal.
Powder Mixing: The first step in manufacturing sintered metal parts is the mixing of the metallic powder. This powder can be composed of pure metals like iron or copper, or alloys such as bronze, brass, or steel. The choice of powder type (e.g., sponge, irregular, spherical, laminar) depends on the specific properties required for the component. The base powder is often mixed with other alloying elements to enhance its properties or to achieve a specific chemical composition.
Compacting: After the powder is mixed, it is compacted into the desired shape using tooling. This is typically done using a die and a press, which applies high pressure to the powder, causing it to form a solid but weak and porous structure. The compacting process is crucial for maintaining the dimensional accuracy of the part and is often followed by additional machining to achieve tighter tolerances.
Sintering: The compacted part is then heated in a process called sintering. This heating is done at a temperature below the melting point of the main constituent of the powder, which allows the particles to bond together without melting. The sintering process involves several stages:
- Heating to Form Martensitic, Crystalline Structures: The metals are heated to a specific temperature to initiate the formation of strong, crystalline structures.
- Compaction with Cold Welds: Sometimes, additional strength is provided by cold welds that occur during the compaction of the powders.
- Addition of Other Elements: Depending on the application, elements like copper powder or cemented carbides may be added to enhance the properties of the compacted materials. This can involve either transient or permanent liquid phase sintering processes.
- Introduction of Liquid and Binder Additives: Finally, a liquid and binder additive may be introduced to fill any remaining pores in the metal, improving its integrity and strength.
The sintering process transforms the compacted, porous part into a strong, integral component. This method is cost-effective and highly repeatable, making it suitable for producing complex net-shape parts with excellent mechanical properties.
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