10 tons per square inch to 250 or more

Powder pressing is the compaction of powders into a geometric form. Pressing is usually performed at room temperature. This creates a solid part called a green compact. The strength of this pressed, unsintered part, (green strength), is dependent on compactability, binders may be used to increase compactability. Typically a green compact can be broken apart by hand but is also strong enough to be handled, gently. The geometry of the green compact is similar to that of the final part, however, shrinkage will occur during the sintering phase of the manufacturing process and must be calculated in.

QTY	Tonnage		QTY	Tonnage
1	250	Hydraulic compacting press	1	100	Federal compacting press
1	80	Bliss compacting press	3	60	Gasbarre compacting presses
1	60	Bliss compacting press	3	60	Multi-action compacting presses
3	35	Johnson compacting presses	3	20	Stokes compacting presses
1	220	Multi-action compacting press	1	40	Fulesday compacting press
1	200	Gasbarre compacting press	1	60	Fulesday compacting press
1	20	Kux compacting press	1	10	Sizing press

Mixed powder is gravity fed in a precision die

Amount of powder needed will be based on the bulk density of the powder and the amount of material in the final part. Bulk density is discussed in the previous section, it is the density of the loose powder by itself. Bulk density is important when measuring powder quantities. The effects of additives such as lubricants must always be calculated. For example, a green compact has a certain amount of lubricants and binders in it that add extra material. During sintering, these lubricants and binders are burned off. Their material is no longer in the part after sintering and this must be a consideration.

To begin the manufacturing process, a certain amount of powder is filled into a die. Rate of die filling is based largely on the flowability of the powder. Powders that flow readily can be poured at higher rates. Pouring can be an automated process.

Materials

Copper
Brass
Copper/Steel
Stainless Steel
Carbon Steel
Nickel Steel
Infiltrated Steel
Low Alloy Steel; Prealloyed Ni, Mo, Mn

Powder is compacted at pressures ranging from 10 tons per sq. in. or as high as 250 or more tons per sq. in.

Controlled Atmosphere

A controlled atmosphere is critical during powder sintering. The purpose of the atmosphere in sintering is to control carburization and decarburization, prevent oxidation and remove existing oxides, prevent unwanted chemical reactions and assist in the burning off of additives. Common atmospheres used for industrial powder processes are carbon monoxide, disassociated ammonia, hydrogen, partially combusted natural gas and inert gases such as argon or helium. Sometimes parts are also sintered in a vacuum. Vacuum sintering is mainly applicable to refractory metals and stainless steel.

Infiltration

Infiltration is the filling of a metal's pores with another metal of lower melting point than the base material. The infiltration metal is heated to a temperature above its melting point but below that of the porous metal part. Liquid metal is allowed to enter into the porous network and solidifies, filling the pores with solid metal. Infiltration can produce parts with special mechanical properties. Iron infiltrated with copper is a common example of this process in manufacturing industry.

Sintering Mechanisms

Sintering occurs by diffusion of atoms through the microstructure. This diffusion is caused by a gradient of chemical potential - atoms move from an area of higher chemical potential to an area of lower chemical potential. The different paths the atoms take to get from one spot to another are the sintering mechanisms

ISO 9001 Certified

Coordinate Measuring Machine (CMM)

An optical comparator (often called just a comparator in context) is a device that applies the principles of optics to the inspection of manufactured parts. In a comparator, the magnified silhouette of a part is projected upon the screen, and the dimensions and geometry of the part are measured against prescribed limits.

The typical 3D "bridge" CMM is composed of three axes, X, Y and Z. These axes are orthogonal to each other in a typical three-dimensional coordinate system. Each axis has a scale system that indicates the location of that axis. The machine reads the input from the touch probe, as directed by the operator or programmer. The machine then uses the X,Y,Z coordinates of each of these points to determine size and position with micrometer precision typically,

Quality Equipment List

ROCKWELL HARDNESS TESTER

OPTICAL COMPARITOR

TINIUS-OLSEN TENSILE TESTER

DENSITY SCALE

WEIGH SCALES

PLUG GUAGES

MICROMETERS

CALIPERS

FLOW METER

TORQUE TESTER

FCPM ALSO WORKS IN CONJUNCTION WITH A CERTIFIED INDEPENDENT LABORATORY FOR TESTING NOT PERFORMED IN-HOUSE

Optical Comparitor

Rockwell Hardness

The Rockwell scale is a hardness scale based on indentation hardness of a material. The Rockwell test determines the hardness by measuring the depth of penetration of an indenter under a large load compared to the penetration made by a preload.

Tensile testing

Tensile testing, is also known as tension testing, is a fundamental materials science test in which a sample is subjected to a controlled tension until failure. The results from the test are commonly used to select a material for an application, for quality control, and to predict how a material will react under other types of forces. Properties that are directly measured via a tensile test are ultimate tensile strength, maximum elongation and reduction in area

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Press Capacity

10 tons per square inch to 250 or more

Mixed powder is gravity fed in a precision die

Powder is compacted at pressures ranging from 10 tons per sq. in. or as high as 250 or more tons per sq. in.

100% hydrogen atmosphere for stainless