Innovation Process
Powder Coating Process
Additive manufacturing (AM), sometimes called metal 3D printing, is considered a newer PM method, although its history dates back to the 1980s. In this method, parts are formed by melting or laser sintering metal powders (as well as other forms of metals, ceramics, and polymers) and additives. What makes these two methods so different from the other PM methods is the layer-by-layer approach taken to build up the part (hence the term additive manufacturing, which refers to the process of adding a layer at a time to form the part). This allows parts to be built a single layer (micrometers thick) at a time based directly on 3D digital models of the part via computer aided manufacturing (CAM). This layered approach is digitally controlled to achieve a high level of precision.
Basics of the Powder Metal Manufacturing Process
Typical PM parts are made in three basic steps: the blending of the metal powder (pulverization), die compaction, and sintering of the product. Additional heat treatment steps may be required after sintering in order to achieve the appropriate density, dimensions, and surface finish.
Pulverization and sieving prepare the metal powders for use in PM. The powders can vary in both shape (some are designed to be spherical) and size. Metallic powders can be produced through one of several different processes, including grinding, crushing, electrolytic deposition, chemical reactions, and atomization. The size and shape of the particles is an important factor when designing a part for manufacturing by PM methods.
Die compaction is accomplished using a pre-determined amount of pressure in relation to the part. This pressure is applied at room temperature, while sintering then begins at elevated temperatures conducted at atmospheric pressure. Note that sintering is performed under strict atmosphere-controlled conditions. After sintering, secondary heat processes are often used to enhance mechanical properties and dimensional precision.
Introduction to Additive Manufacturing/Metal 3D Printing
Additive manufacturing (AM), sometimes called metal 3D printing, is considered a newer PM method, although its history dates back to the 1980s. In this method, parts are formed by melting or laser sintering metal powders (as well as other forms of metals, ceramics, and polymers) and additives. What makes these two methods so different from the other PM methods is the layer-by-layer approach taken to build up the part (hence the term additive manufacturing, which refers to the process of adding a layer at a time to form the part). This allows parts to be built a single layer (micrometers thick) at a time based directly on 3D digital models of the part via computer aided manufacturing (CAM). This layered approach is digitally controlled to achieve a high level of precision.
Both processes are explained in detail here after.
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