Powder materials and processing- Assignment 1

1. Powders are used for forming many automotive components. Identify one such component
and give the chief performance requirement.

The most significant application for iron powder is automotive OEM and aftermarket brake pads. Other
applications include trains, commercial vehicles, clutch facings, aircraft brake pads and other industrial
uses.

 Iron powder is used as a filler in friction materials, while also adding significant thermal transfer
properties, a factor that helps to dissipate heat, which improves performance and reduces wear
on the brake pad.

 The iron powders provide excellent bonding in the friction material matrix. The high internal
porosity of these products helps minimize brake noise, brake rotor wear and brake pad wear to a
greater extent than other metallic alternatives.

Commonly used grades are coarse iron powders IRONR-12 and IRON20/80-19.

2. The total work needed for mechanical milling a brittle metal is proportional to the inverse square
root of the particle size. What is the relative difference in required energy to form a 10 μm and a 1 μm
powder?

W= 1/√(Particle size)

Relative difference= (1/√1) - (1/√10) = 0.683 or 68.3%

3. What are the key differences between ceramic and metal powders that influence the
processing decisions?

Metals and ceramics are processed in a similar way. Metals powders are sintered and and in the case of
ceramics, they are fired. Ceramics, the powder is first mixed with water and to produce a slurry and then
molded and fired. Ceramics have to be glazed and finished. In case of ceramics, dimensional tolerance is
an important factor. The shrinkage is very high because of huge change in density.

Ceramics have high melting point, hardness, poor conductivity, low ductility, metal powders have good
reactivity, flow ability, compressibility.

4. Why is it not possible to use casting technologies for tungsten (W)? Provide at least TWO reasons.

Tungsten has a very high melting point and highly reactive to form oxides. Hence it is very difficult to use
casting technology.
Tungsten tends to become very brittle and hence not ideal for casting.
5. In a certain study of mechanical alloying in attrition mills at a powder production facility it was
established (empirically) that the grinding time t needed to obtain a homogenous powder product
depends on the agitator rotational speed N(revolutions per unit time) as follows:
t= C (d2/N1/2) where
d is the grinding ball diameter and C is an empirical constant for a particular powder material ,
grinding media, and the mill.
A tungsten - copper (W-Cu) composite powder is mechanically alloyed for 4 hours in the attrition
mill at 120 RPM. To attain the same level of attrition /alloying in 1 hour, estimate what rotation rate
should be selected?

T1*n11/2=t2*n21/2

4*1201/2=1* n21/2
n21/2= 43.818
n2= 1920rpm