Powder metallurgy case study

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Powder metallurgy PM is a term covering a wide range of ways in which materials or components are made from metal powders. PM processes can avoid, or greatly reduce, the need to use metal removal processes , thereby drastically reducing yield losses in manufacture and often resulting in lower costs. Powder metallurgy is also used to make unique materials impossible to get from melting or forming in other ways. A very important product of this type is tungsten carbide WC. WC is used to cut and form other metals and is made from WC particles bonded with cobalt.
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History of Powder Metallurgy & Metal Powder Products - & Their Future

In this paper, we attempt to make an exploratory step in this regard by presenting a case study that exemplifies how crack simulations can be harnessed to solve real powder metallurgy manufacturing problems. The part subjected to the study is a multilevel adapter whose design to production process proved problematic to the manufacturer, to the point that simplifications in the geometry of the part were to be made. The goal here is, through finite element simulations, to clarify the reasons behind the difficulties in ejecting free crack compacts, to understand the connection of such difficulties with the geometry modifications introduced in the design and to make recommendations on the prevention of similar problems in other situations. The Spanish Ministry of Science and Innovation and the Catalan Government Research Department are gratefully acknowledged for financial support under grant nos. Celeiro for their endless patience in helping the authors understand the intricacies of CNC press machines.
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Case study: Conventional powder metallurgy replaces machined assembly

Novomet is unique in the artificial lift industry because it uses superior powder metallurgy manufacturing to produce parts with exceptional precision and surface smoothness that improve efficiency in electrical submersible pumping ESP systems. Compared to casting typical manufacturing process for most ESP components , powder metallurgy manufacturing delivers superior surface smoothness that reduces fluid friction, produces less waste, and enables complex component design that is simply not possible using even the most advanced casting techniques. We use powder mixtures that contain a variety of metals including iron graphite, stainless steel, and various alloys.
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Pistons are commonly made of a cast aluminum alloy for excellent and lightweight thermal conductivity. Thermal conductivity is the ability of a material to conduct and transfer heat. Aluminum expands when heated and proper clearance must be provided to maintain free piston movement in the cylinder bore.
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