From powder to solid component – sintering

Sintering is a manufacturing process for producing metal or ceramic parts. Sintering technology as a manufacturing process for metal components is ideal for workpieces with special (usually simple) geometries, such as compact gears, pinions, bearings, or housings, which can be produced ready for installation, even with heat treatment.

The sintering process initially allows for shaping without heating the material. The metal powder is pressed into green compacts in dies at varying pressures, and then sintered at temperatures just below the melting point. During this process, the powder particles fuse together at their contact surfaces, giving the workpiece its dimensions and design. Thanks to a final calibration blow, the workpieces exhibit very high dimensional accuracy.

Sintering is an effective, environmentally friendly, and economical process, especially for high-volume production involving a wide variety of metals.

Manufacturing Processes

2

The powders are then mixed together in the ratio of the desired alloy.

Mixing

1

The process begins with powder production. Metallic powder is produced by water atomization. Because the powder is cooled quickly here, it becomes spattering and can become mechanically entangled during subsequent pressing.

Powder Production

3

The pulverizer is pressed into green compacts in dies under high pressure using several press dies.

Pressing

4

This is followed by the actual sintering of the green compacts below the melting temperature.

Sintering

5

The final calibration blow eliminates even the smallest inaccuracies and greatly increases dimensional accuracy.

Calibrate

6

Finally, quality control is performed, during which the component is checked for compliance with the drawing specifications and material properties.

Quality Control

2

The powders are then mixed together in the ratio of the desired alloy.

Mixing

1

The process begins with powder production. Metallic powder is produced by water atomization. Because the powder is cooled quickly here, it becomes spattering and can become mechanically entangled during subsequent pressing.

Powder Production

3

The pulverizer is pressed into green compacts in dies under high pressure using several press dies.

Pressing

4

This is followed by the actual sintering of the green compacts below the melting temperature.

Sintering

5

The final calibration blow eliminates even the smallest inaccuracies and greatly increases dimensional accuracy.

Calibrate

6

Finally, quality control is performed, during which the component is checked for compliance with the drawing specifications and material properties.

Quality Control

Advantages of Sintering

The sintering manufacturing process has several advantages.

Sintering allows for the combination of raw materials that would otherwise be very difficult or impossible to combine into a new material.
High dimensional and shape accuracy is achieved, so that post-processing is minimal or completely eliminated.
Furthermore, the material is utilized optimally, resulting in minimal waste.

Use of Sintered Products

Sintered products are found in various industrial sectors. They are used, for example, in power electronic devices such as switching power supplies, filters, or antennas. They are also found in components such as cutting ceramics, electro-porcelain, or ceramic magnets. Sintered parts are found in large series, especially in the automotive industry, for example, in the form of components for engines and transmissions, as well as tool parts or indexable inserts made of hard metals. Dental technology uses sintering to produce ceramic teeth and veneers.

The development and optimization of new metal powders is constantly expanding the areas of application for sintered products.