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Joseph Tunick Strauss HJE Company, Inc. Glens Falls, South Glens Falls, and Queensbury, NY

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Joseph Tunick Strauss HJE Company, Inc. Glens Falls, South Glens Falls, and Queensbury, NY

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    1. P/M (Powder Metallurgy) Joseph Tunick Strauss HJE Company, Inc. Glens Falls, South Glens Falls, and Queensbury, NY

    2. Powder Metallurgy (P/M)

    7. I Introduction (cont.) POWDER METALLURGY (P/M): Full-scale Industrialization in past 50 years >$1.8 Billion per year in North America P/M Processing has Shown Continuous Annual Growth for the Past 50 Years by 1) Replacing Existing Technologies 2) "DFM: Designed for Manufacturability" Keep in mind that powder cost more than equivalent cast or wrought material

    8. II General Summary of The Science of P/M P/M consists of three fundamental steps: a) Powder Production b) Powder Consolidation c) Sintering

    9. II General Summary of The Science of P/M a) Powder Production Atomization Electrolytic, precipitation Mechanical Chemical, reduction

    10. II General Summary of The Science of P/M a) Powder production by Atomization: Disintegration of liquid stream by a second fluid Gas Atomization Spherical powder particles Good "flowability" Water Atomization: Irregular powder particles Good compactability

    16. II General Summary of The Science of P/M c) Sintering: Heat treatment to promote metallurgical integrity Metallurgical Bonding Densification (shrinkage) Pore Elimination

    19. III P/M Manufacturing Techniques Net Shape Processing Die Compaction Use water atomized powder (irregular shape) Rigid tooling: tool steel, WC/Co Pressures up to 60 tons/square inch Production > 10,000 parts High tolerance, 0.001 "/" possible High productivity Controlled porosity, density (85% to 90%)

    22. III P/M Manufacturing Techniques Net Shape Processing MIM (Metal Injection Molding) Plastic Injection Molding + Powder Metallurgy (P/M) Complex Shapes High density metal parts (> 95%) Economy of Scale (high productivity) Good tolerance, .003 "/" possible, .005-.008 "/" typ. Competes with investment casting and discrete machining

    27. P/M Press-Sinter-Forge vs. Power Forge Better material utilization Fewer tool sets Reduction of secondary machining operations Large end bearing bore and mating flats Eliminate balancing

    29. IV Applications, General Case Studies: Orthodontia Brackets MIM vs. Discrete machining and Investment casting: Elimination of all machining operations Better material utilization (no chips, sprues, etc) Able to produce smaller parts than investment cast Able to produce more complex geometries than machining Massive reduction in labor Complete payback in about 2 years

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