Sintering is a crucial process in manufacturing that transforms powder grains into strong, cohesive parts.
What Happened During Sintering? 7 Key Stages Explained
1. Formation of the Green Part
A primary part powder blend, with a bonding agent, is formed into a desired shape. The bonding agent, typically a wax or polymer, helps in maintaining the shape by sticking the powder together.
2. Evaporation or Burn-off of the Bonding Agent
When the green part is heated, the bonding agent evaporates or burns away, preparing the part for the next stage.
3. Fusion of Particles
The temperature is raised sufficiently, either causing the primary particles to slightly melt and fuse at their surfaces or allowing an intermediate bonding agent like bronze to melt and bond between the particles. This fusion leads to the formation of a strong, cohesive structure.
4. Pre-heating
In this initial stage, the lubricant used in the part melts, exudes to the surface, or vaporizes. Proper de-lubrication is crucial to prevent issues like blistering and sooting during the subsequent sintering stage.
5. Sintering
The sintering stage involves a three-stage process: formation of the green part, evaporation or burn-off of the bonding agent, and fusion of particles.
6. Sintering Conditions
Sintering is typically performed in continuous furnaces at temperatures between 750 and 1300°C, depending on the material and desired characteristics. The process operates at temperatures lower than the base metal melting point, facilitating welding of particles and alloying elements through solid-state diffusion.
7. Cooling
After sintering, the product is cooled under controlled conditions to solidify into a rigid and cohesive structure. The rate of cooling can be adjusted to influence the properties of the final part, such as hardness and ductility.
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