The disadvantages of powder metallurgy include size limitations, challenges in producing complex-shaped parts, and generally lower strength and ductility compared to cast irons or forged parts.
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Size Limitations: Powder metallurgy (PM) processes are constrained by the size of the presses used. The largest presses in the industry are around 1,500 tons, which limits the practical size of parts to about 40-50 square inches of planar area. More commonly, presses are in the 500-ton range, further restricting the size of parts that can be produced. This limitation can make certain large-scale designs impossible to produce using PM.
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Complex-Shaped Parts: While PM can theoretically produce any shape, complex designs can be challenging to manufacture. Although high-skill manufacturers can overcome this challenge, the complexity of the design can increase the difficulty and cost of production. This limitation might require additional design considerations or compromises to fit within the capabilities of PM.
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Strength and Ductility: PM parts are generally not as strong or ductile as parts made from cast irons or forged materials. This is a significant disadvantage in applications where high strength and ductility are critical. The lower strength and ductility might necessitate the use of more material or alternative manufacturing methods for critical load-bearing components.
These disadvantages highlight the need for careful consideration of the design and material requirements when choosing powder metallurgy as a manufacturing process. Despite these challenges, powder metallurgy remains a valuable method for producing parts with specific material properties and geometries, particularly in applications where other manufacturing methods are impractical or too costly.
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