Heating in the sintering operation is achieved through a controlled thermal cycle. This cycle involves raising the temperature of the compacted part to a level below the melting point of the base metal.
The process is typically conducted in specialized furnaces. These include continuous furnaces or tunnel kilns. These furnaces are designed to maintain precise temperature and atmosphere conditions.
5 Key Stages Explained
1. Preheating
In the preheating zone of a tunnel kiln or furnace, the temperature is gradually increased. This stage primarily focuses on removing lubricants and other organic materials from the green part.
Adequate preheating is crucial. It prevents defects like blistering and sooting during the subsequent sintering stage.
2. Sintering
The sintering zone is where the actual consolidation of particles occurs. Here, the temperature is raised to a point where atomic diffusion happens, allowing the particles to fuse together.
This temperature is carefully controlled to be below the melting point of the base metal. It typically ranges between 750 and 1300°C, depending on the material and desired properties.
The high temperature facilitates welding of particles and alloying through solid-state diffusion mechanisms.
3. Cooling
After the sintering process, the parts are moved to the cooling zone. They are gradually cooled down.
The rate of cooling can significantly affect the final properties of the sintered part. These properties include its hardness and strength.
Controlled cooling can prevent sudden stresses and cracks. It ensures the integrity of the part.
4. Pressureless Sintering
This method involves sintering without applying external pressure. It relies solely on heating to achieve particle bonding.
It is commonly used for metal-ceramic composites.
5. Induction Sintering
This technology uses electromagnetic induction to heat the material. It can help in reducing harmful substances in the atmosphere.
It also improves the purity and mechanical properties of the sintered part.
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