Manufacturing Processes Powders metallurgy, Ceramics, Glasses
Manufacturing Processes Powders metallurgy, Ceramics, Glasses
Manufacturing Processes Powders metallurgy, Ceramics, Glasses
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<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
<strong>Powders</strong> <strong>metallurgy</strong>, <strong>metallurgy</strong>,<br />
<strong>Ceramics</strong>, <strong>Glasses</strong>
Contents<br />
Powder Metallurgy(분말야금)<br />
1. Powder production<br />
2. Blending or mixing<br />
3. Compaction<br />
4. Sintering<br />
Ceramic<br />
1. Mixing particles with additives<br />
2. Shaping<br />
3. Drying & Firing<br />
Glass<br />
1. Plate, Tubing<br />
2. Blowing, Pressing<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Powder Metallurgy Usage<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
PM1: http://www.youtube.com/watch?v=n_FW7Q2xO5o<br />
http://www.hmptech.com
Powder Metallurgy<br />
1. Powder production<br />
2. Blending or mixing<br />
3. Compaction<br />
4. Sintering<br />
5. Finishing operations<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
PM2: http://www.youtube.com/watch?v=iQIsk44JUYs&feature=related<br />
http://www.youtube.com/watch?v=1Mjsi2F2MrY
Powder Production<br />
Atomization (입자화)<br />
• Liquid‐metal stream is broken into powder by water jet.<br />
Reduction (환원)<br />
• Metallic oxides are reduced to the metallic state.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Particle size and shape<br />
• Particle size is measured and controlled by screening.<br />
• Particle shape is expressed by aspect ratio or shape<br />
factor.<br />
• Size and shape of particles affect the processing<br />
characteristics of the powder.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Blending metal powders<br />
• Blending (mixing) powders is the second step, and the<br />
purposes are:<br />
1. to impart physical and mechanical properties and<br />
characteristics to the P/M part<br />
2. obtain uniformity from part to part<br />
3. lubricants are mixed to improve flow characteristics<br />
4. binders are used for sufficient green strength<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Compaction(압축) of metal powders<br />
• <strong>Powders</strong> are pressed into shapes using dies and presses.<br />
• Obtain the required shape, density and particle‐to‐<br />
particle contact.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Compaction of metal powders<br />
• The density after compaction<br />
depends on:<br />
1. compaction pressure<br />
2. powder composition<br />
3. hardness of the powder<br />
• Higher the density, higher<br />
the strength and<br />
elastic modulus of the part.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Pressure distribution in powder<br />
compaction<br />
• Pressure distribution along length of the compact.<br />
p<br />
x<br />
<br />
μ : powder‐wall friction coef.<br />
k : the inter‐particle friction coef.<br />
x/D : length‐to‐diameter ratio<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
p<br />
0<br />
e<br />
4kx<br />
D
Isostatic pressing<br />
• <strong>Powders</strong> are subjected to hydrostatic pressure in order<br />
to to achieve uniform compaction.<br />
• In cold isostatic pressing (CIP), metal powder is placed<br />
in a flexible rubber mold.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Isostatic pressing<br />
• In hot isostatic pressing (HIP), a container is made of<br />
high‐melting point sheet metal and the pressurizing<br />
medium is an inert gas.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Sintering<br />
• Sintering (소결) is where compacted metal powder is<br />
heated to below its melting point for the bonding of the<br />
individual metal particles.<br />
• Sintered density increases with temperature and time.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Metal Injection Molding (MIM)<br />
1. Mixing: metal + polymer<br />
2. Injection monding<br />
3. Debinding<br />
4. Sintering<br />
• Ceramic Injection Molding (CIM)<br />
1. Mixing: ceramic + polymer<br />
…<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
MIM: http://www.youtube.com/watch?v=BxJaq-WpIIc&feature=related
Design for Powder Metallurgy<br />
1. Simple & uniform shape<br />
2. Easy ejection from die<br />
3. Large tolerance reduce cost<br />
4. Avoid sharp radius<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Economics of Powder Metallurgy<br />
• The cost depends on method of powder production, its<br />
quality and quantity purchased.<br />
• Due to high cost of punches, dies and equipment for<br />
P/M processing, production volume must be high.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Ceramic usage<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
Pottery<br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
Aerospace<br />
Memory<br />
Medical
Ceramic usage<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
Electric resistance<br />
Wear resistance<br />
Art<br />
High temperature
<strong>Ceramics</strong><br />
• <strong>Ceramics</strong> are compounds of metallic and non‐metallic<br />
elements.<br />
• Bonding between atoms can be covalent and ionic.<br />
• Various types of ceramics are:<br />
1. Oxide ceramics O: Alumina Al2O3, Zirconia ZrO2 2. Carbides C: Tungstem carbides WC, Silicon carbide SiC<br />
3. Nitrides N: Cubic boron nitride cBN, Titanium nitride TiN, Sialon, Cermets<br />
4. Silica SiO 2<br />
5. Nanophase ceramic<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
General properties of ceramics<br />
• <strong>Ceramics</strong> are brittle, have high compressive strength and<br />
hardness at elevated temperatures, high elastic modulus,<br />
low toughness, low density, low thermal expansion, and low<br />
thermal and electrical conductivity.<br />
1. Mechanical properties<br />
• Sensitivity to cracks, impurities and porosity<br />
• Strength in tension is lower than compressive strength.<br />
2. Physical properties<br />
• Low specific gravity and have high melting temperatures.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Ceramic process<br />
1. Crushing raw materials into very fine particles<br />
2. Mixing particles with additives<br />
3. Shaping<br />
4. Drying<br />
5. Baking in fire<br />
6. Finishing<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
Knife: http://www.youtube.com/watch?v=JFnT5INymiY&feature=related<br />
Toilet: http://www.youtube.com/watch?v=vaUFN-q3_mk&feature=related
Diamond<br />
• Has a covalently bonded structure and is the hardest<br />
substance.<br />
• It is brittle and decompose in air at about 973 K.<br />
• Applications include cutting tools, window of laser.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Glass<br />
• Glass is an amorphous solid with the structure of a liquid.<br />
• All glasses contain at least 50% silica SiO2. • They are resistant to chemical attacks and ranked by their<br />
resistance to acid, alkali or water corrosion.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Mechanical properties<br />
• Consider to be linearly elastic and brittle.<br />
• Bulk formed glass has low strength(
Float method<br />
1. Molten glass from the furnace is fed into a bath of<br />
molten tin.<br />
2. The glass floats on the tin bath an then moves over<br />
rollers and is cut to glass plates.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
Plate glass: http://www.youtube.com/watch?v=j4RzW2_vbHI
Glass tubing<br />
Air is blown through the mandrel to make the tube<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
Glass Blowing<br />
Glass bottle is made by blowing<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
Bottle: http://www.youtube.com/watch?v=NVKcISj2LfA&feature=related
Glass Pressing<br />
Glass vessel is made by pressing.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim<br />
Block: http://www.youtube.com/watch?v=pEd2Oni88uY
Graphite<br />
• Graphite is a layered structure of carbon C.<br />
• It is brittle, electrical thermal conductor, has resistance<br />
to chemical thermal shock.<br />
• Low frictional properties allow it to be a solid lubricant,<br />
abrasive but a poor lubricant in a vacuum.<br />
• Special structure : Graphite fiber and Carbon nano tube.<br />
<strong>Powders</strong>, <strong>Glasses</strong><br />
<strong>Manufacturing</strong> <strong>Processes</strong><br />
© Pearson Pearson<br />
& GNU Su-Jin Su Jin Kim
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