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Forming processes
This unit addresses aspects of the following syllabus outcomes:
A student:
H1.2 differentiates between properties of materials and justifies the selection of materials, components and processing in engineering.
H2.1 determines suitable properties, uses and applications of materials in engineering.
Extract from Stage 6 Engineering Studies Syllabus. © Board of Studies. NSW, 1999.
Powder forming (powder metallurgy)
The process of powder forming involves the production of machine components from metal powders. It is often referred to as the powder metallurgy process.
The powder forming process is an extremely effective method of manufacturing structural metal components with high-dimensional accuracy on a mass production basis. The process provides net or near-net shapes and ready-to-assemble components for technical applications for nearly all industry sectors.
Compared to other traditional metal forming or manufacturing processes, e.g. machining, hot forging, casting, fine-edge blanking, the sintering process offers competitive engineering solutions in terms of technical performance and manufacturing costs.
As a result, powder metallurgy is developing faster than other metal forming technologies.
The basic powder forming production process is relatively easy to follow. Essentially, it involves compacting metal powders into a specific shape, then heating the blank until the powders fuse into a solid mass.
Activity 1
Visit the Internet site www.gknsintermetals.com 
and click on the graphic to see how the GKN Company turns metal powders
into finished components. Pass your mouse over each stage. Left-click to reveal
an explanation of what happens at each stage of the process.
List the stages in order of production.
Activity 2
From the products section of the GKN Sinter Metals web site, list some examples of applications where powder formed products are used.
Activity 3
Use information from GKN Sinter Metals processes section to identify the main reasons which make the powder forming process attractive to the design engineer.
Activity 4
Access the GKN Sinter Metals to locate information on the four powder forming stages: powder blending, powder compaction, sintering, sizing and coining.
Download the following table and use the information you have found about the powder forming stages to complete it.
| Powder forming stages | Process overview | Purpose | Results |
|---|---|---|---|
| Powder blending | |||
| Powder compaction | |||
| Sintering | |||
| Sizing and coining |
Activity 5
Use information at GKN Sinter Metals website to help you answer the following. In addition to the links given above, the Metal Injection Moulding link will assist.
Download the following table. Complete the table using your knowledge of powder forming processes and other forming processes you have investigated. Check your responses against the answer given.
| Design limitations | Mechanical properties | Material utilisation | |
|---|---|---|---|
| Powder forming press and sinter | |||
| Metal injection moulding | |||
| Precision powder forging | |||
| Drop forge | |||
| Casting | |||
| Machining | |||
| Stamping |
Activity 6
Download the following table. Complete the table using your knowledge of powder forming processes and other forming processes you have investigated. Check your responses against the answer given.
| Advantages | Disadvantages | |
|---|---|---|
| Powder forming press and sinter | ||
| Metal injection moulding | ||
| Powder forging | ||
| Drop forging | ||
| Casting | ||
| Machining | ||
| Stamping |
|