Powder Metal Services Specifications

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Capabilities

Forming Process

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Mechanical Pressing

The compacting process places a controlled amount of mixed powder, approximately 2-1/2 times finish volume, into the die. Compression is conducted by punches moving simultaneously from above and below at pressures ranging between 20 and 50 tons per square inch. Dimensions and density are closely controlled in this process. The compacted component is called a "green compact".

CIP

Cold isostatic pressing (CIP) of metal powders in a flexible rubber mold under high pressure (up to 60,000 psi) to form a part. The parts are subsequently sintered.

HIP

Hot isostatic pressing (HIP) of metal powders in a welded metal mold under high pressure (up to 60,000 psi) to form a high density part or preform. Parts can reach or closely approach theoretical density using a HIPing process.

Magnetic Pressing

Metal powder is loaded into an electrically conductive tube (such as copper, aluminum, or steel). The tube is placed at the center of the electromagnetic coil, and a current is pulsed through the coil, creating high magnetic pressure radially around the tube. The kinetic energy of the tube wall presses the powder into a high-density part.

Metal Injection Molding (MIM)

Metal injection molding (MIM) is a powder metallurgy process used for manufacturing metal parts. Although MIM uses powder metal, it is nothing like conventional powder metal process. The metal powders used in MIM are 10-100 times smaller than in powder metal processes. Also, the end product of MIM is much higher in density (greater than 95% theoretical density). Unlike powder metal, products manufactured by MIM can be case or through hardened, painted, and drilled and tapped. Metal injection offers the same benefits and features of plastic and rubber molding, but produces a much stronger end product. Metal injection molding can provide a substantial cost savings over conventional metal machining options. Applications for MIM parts include surgical tools, automotive locks and actuators, firearm components, computer hard disk drives and electrical connectors.

Roll Compacting

The progressive compacting of metal powders by the use of rolling mill. Synonymous with Powder Rolling.

Sintering

The metallurgical bonding of particles in a powder mass or compact resulting from a thermal treatment at a temperature below the melting point of the main constituent.

Slip Casting

A method of forming metal shapes by pouring a stabilized water-suspension of metal powders into the shaped cavity of a fluid absorbing mold, diffusing the liquid into the mold wall, removing the casting from the mold and sintering.

Other

Other unlisted, specialized, or proprietary forming process.

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Tables:

Material Density Table

Material	Theoretical Density (g/cc)	Density Range (g/cc)	% Theoretical Density
Aluminum	2.71 - 2.80	2.68 - 2.80	Fully Dense
		2.439 - 2.77	90 - 99%
		2.30 - 2.52	85 - 90%
		< 2.30	<85%
Brass	8.47	8.39 - 8.47	Fully Dense
		7.62 - 8.39	90 - 99%
		7.2 - 7.62	85 - 90%
		< 7.2	<85%
Bronze	8.78 - 8.86	8.69 8.86	Fully Dense
		7.90 - 8.77	90 - 99%
		7.46 - 7.97	85 - 90%
		< 7.46	<85%
Copper / Nickel	8.83	8.74 - 8.83	Fully Dense
		7.95 - 8.74	90 - 99%
		7.51 - 7.95	85 - 90%
		< 7.51	<85%
Molybdenum	10.3	10.2 - 10.3	Fully Dense
		9.27 - 10.2	90 - 99%
		8.8 - 9.27	85 - 90%
		< 8.8	<85%
Stainless Steel	7.92	7.84 - 7.92	Fully Dense
		7.13 - 7.84	90 - 99%
		6.73 - 7.13	85 - 90%
		< 6.73	<85%
Steel	7.86	7.78 - 7.86	Fully Dense
		7.07 - 7.78	90 - 99%
		6.68 - 7.07	85 - 90%
		< 6.68	<85%
Titanium Alloy	4.43 - 4.51	4.39 - 4.51	Fully Dense
		3.99 - 4.46	90 - 99%
		3.77 - 4.06	85 - 90%
		< 3.77	<85%
Tungsten	19.3	19.1 - 19.3	Fully Dense
		17.4 - 19.1	90 - 99%
		16.4 - 17.4	85 - 90%
		< 16.4	<85%

Materials


	Material
	Your choices are...
	Aluminum		Aluminum is a bluish, silver-white, malleable, ductile, light trivalent, metallic element that has good electrical and thermal conductivity, high reflectivity, and resistance to oxidation.
	Brass / Bronze		Brass comes with good strength, excellent high temperature ductility and reasonable cold ductility, good conductivity, excellent corrosion resistance, good bearing properties and low magnetic permeability. Sintered bronze is a porous material, which can be impregnated with oil, graphite or PTFE. Not suitable for heavily loaded applications but useful where lubrication is inconvenient.
	Composite		Composite materials typically consist of a matrix and a dispersed, fibrous or continuous second phase. The second phase may reinforce (strengthen or stiffen), alter electrical or magnetic properties or enhance wear or erosion resistance.
	Copper		A common reddish metallic element that is ductile and malleable and is one of the best conductors of heat and electricity.
	Nickel Alloy		Will vary per application, as nickel is a constituent of many alloys.
	Refractory Metal		Refractory metals such as tungsten, molybdenum and tantalum.
	Stainless Steel		Stainless steel is chemical and corrosion resistant and can have relatively high-pressure ratings.
	Steel		A commercial iron that contains carbon in any amount up to about 1.7 percent as an essential alloying constituent. It is malleable when under suitable conditions, and is distinguished from cast iron by its malleability and lower carbon content.
	Titanium Alloy		Titanium is a hard, lustrous, silvery, element that is relatively abundant in the Earth's crust. It is known for its lightness, strength, and corrosion resistance. For this reason it is used widely in the aerospace industry and the medical fields (e.g., replacement joints). When alloyed with other metals, especially steel, it adds strength and oxidation resistance.
	Other		Other unlisted, specialized, or proprietary material.
	Search Logic:		All products with ANY of the selected attributes will be returned as matches. Leaving all boxes unchecked will not limit the search criteria for this question; products with all attribute options will be returned as matches.

	Density Ratio (% Theoretical Density)		The ratio of the determined density of a compact to the absolute density of metal of the same composition, usually expressed as a percentage. Synonymous with % theoretical density. Material properties such as elongation, yield strength, corrosion resistance, and magnetic properties are directly related to density.
	Your choices are...
	Fully Dense		Fully density powder metal parts provide the ‘ultimate’ physical properties for conventionally compacted powder metal materials. The density ratio is 99% to 100% of the theoretical density. See Material Density Table below for reference.
	90% to 99% T.D.		Metal powder is consolidated under pressure to a compaction density between 90% and 99% theoretical density. This is considered high density and is manufactured using presses operating with very high pressures. See Material Density Table below for reference.
	85% to 90% T.D.		Metal powder is consolidated under pressure to a compaction density 85% to 90% theoretical density. This is considered high density and is manufactured using presses operating with very high pressures. See Material Density Table below for reference.
	< 85% T.D.		Metal powder is consolidated under high pressure to a compaction density of less than 85%. These densities can be achieved through conventional powder metal manufacturing technologies. See Material Density Table below for reference.
	Open Porosity Material		Porosity is a sponge-like area in an otherwise sound metal part. Porosity is always present in powdered or sintered metal parts. Porosity can be found as continuous, blind, or totally enclosed. 'Continuous' porosity extends completely through the wall thickness of a metal part, causing a leakage path. 'Blind' porosity is connected only to one side of the part wall. 'Totally enclosed' porosity is completely isolated within the wall thickness of a part. When castings are machined, both 'blind' and 'totally enclosed' porosity are often opened-up, becoming 'continuous' porosity and allowing leakage. See Material Density Table below for reference.
	Search Logic:		All products with ANY of the selected attributes will be returned as matches. Leaving all boxes unchecked will not limit the search criteria for this question; products with all attribute options will be returned as matches.

Services



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	Assembly Services		Vendor has ability and facility to do part assembly.
	Design Assistance		Vendor has employees on staff to aid in the design and development of new parts.
	Extrusion		Conversion of a billet into lengths of uniform cross-section by forcing metal through a die orifice of the desired cross-sectional outline.
	Forging		In the forging process, metal is shaped by pressing, pounding, or squeezing under very high pressure, to form parts called forgings. Forging processes include cold forging or heading, impression or closed die, open die, and seamless rolled ring.
	Heat-treating		Heat treatment involves heating a part to its austenizing temperature (typically 1550°F) and quenching it (rapid cooling) to achieve greater strength and hardness.
	High Volume Production		A level of production that requires highly automated processes.
	Oil Impregnating		Oil impregnation is the process of impregnating powder metal parts with a heavy gear oil to make them self-lubricating.
	Prototype / Short Run		Vendor is willing to supply parts at lower quantity levels for prototypes or market entry, or short runs.
	Resin / Plastic Impregnating		Resin impregnation fills the porosity of a part with a resin to create a pressure-tight part for hydraulic applications, which can withstand several thousand PSI, to improve machinability, or to allow electroplating.
	Secondary Machining		Vendor has an internal or associated machine shop for production secondary machining.
	Sinter Brazing		Sinter brazing is the process of joining two or more pieces of an assembly by brazing them during sintering. Sinter brazing yields strong and complex powder metal assemblies. When sinter brazing individual components of an assembly are compacted separately; components are assembled prior to sintering; and the assembly is sintered, allowing the braze material to melt and flow between the joint surfaces of the individual components, bonding them together. Parts that typically undergo sinter brazing include transmission hubs and piston assemblies.
	Sinter Hardening		Sinter-hardening is the combination of sintering and hardening in one step. This has reduced the production costs of low alloy steel parts, which need post sintering heat treatment. This results in a homogeneous martensitic structure in the PM steels. Close dimensional tolerances are maintained in the sinter-hardened parts thus eliminating the need for sizing.
	Tool / Mold Making		Vendor can build tools or molds, or can assist in locating a toolmaker.
	Other		Other unlisted, specialized, or proprietary secondary services.
	Search Logic:		All products with ANY of the selected attributes will be returned as matches. Leaving all boxes unchecked will not limit the search criteria for this question; products with all attribute options will be returned as matches.

Location



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	North America		Companies are located in the United States, Canada or Mexico.
	United States Only		Companies are located in the United States.
	Northeast US Only		Companies are located in the Northeast United States, namely Connecticut, Maine, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island and Vermont.
	Southern US Only		Companies are located in the Southern United States, namely Alabama, Arkansas, Delaware, Florida, Georgia, Kentucky, Louisiana, Maryland, Mississippi, Missouri, North Carolina, Oklahoma, South Carolina, Tennessee, Texas, Virginia, Washington D.C., and West Virginia.
	Southwest US Only		Companies are located in the Southwest United States, namely Arizona, California, Colorado, Nevada, New Mexico and Utah.
	Northwest US Only		Companies are located in the Northwest United States, namely Idaho, Montana, Oregon, Washington and Wyoming.
	Midwest US Only		Companies are located in the Midwest United States, namely Illinois, Indiana, Iowa, Kansas, Michigan, Minnesota, Nebraska, North Dakota, Ohio, South Dakota and Wisconsin.
	Canada Only		Companies are located in Canada.
	South / Central America Only		Companies have facilities in South American countries such as Argentina, Brazil, or Chile; or in Central American countries such as Costa Rica, Honduras, Panama, etc.
	Europe Only		Companies are located in Europe, namely Germany, Ireland, Italy, United Kingdom, etc.
	South Asia Only		Companies are located in South Asia, namely India, Pakistan, Nepal, etc.
	Near East Only		Companies are located in the Near East, namely Egypt, Israel, Saudi Arabia, etc.
	East Asia / Pacific Only		Companies are located in East Asia, namely China, Japan, Taiwan, etc.
	Other		Other unlisted country or region.
	Search Logic:		Products with the selected attribute will be returned as matches. Leaving or selecting "No Preference" will not limit the search criteria for this question; products with all attribute options will be returned as matches.

Powder Metal Services Specifications

Forming Process:

Material:

Density Ratio (% Theoretical Density):

Services:

Location:

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