Guide to Sintered Metal Products

Metal sintering is a manufacturing process that involves heating powdered metal particles until they bind together. This technology is used to precisely produce complex metal pieces. During sintering, the powder is heated below its melting point, allowing it to bond and form a robust component. It is a widely employed method because it is environmentally friendly, low cost, and can create durable components.

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Allied Sinterings has been expertly crafting powdered and sintered metal goods since ! Our team utilizes top-notch powders and materials, and clients in diverse sectors regard our proficiency in handling complex shapes. Moreover, our Danbury plant has three sintering furnaces and 42 high-precision Dorst compacting presses from Germany. We also have a complete in-house tool room and tumbling and finishing department.

The Sintering Process in Powder Metallurgy

Here is a detailed breakdown of the sintering process:

2. Ceramics

Most ceramic processes are considered either sintering or close to sintering. A selection of commonly 3D (SLS or paste deposited) printed and then sintered ceramics are: alumina, aluminum nitride, zirconia, silicon nitride, boron nitride, and silicon carbide. Ceramics are generally sintered by compression or press molding.

3. Polymers

Sintered polymers fall into two categories: large and small particle sintering. Large particle sintering with high porosity is commonly applied as filtration and pneumatic silencer materials and as flow diffusion controllers. These include polyethylene, polypropylene, and polytetrafluoroethylene. Small particle sintered polymers are used in 3D printing in processes such as selective laser sintering. This is used to produce integrated and high-strength components with near-native material properties and near-zero porosity. Examples are polyamides, polystyrene, thermoplastic elastomers, and polyether-ether ketones. Xometry's most popular process is selective laser sintering. You can get an instant quote on it any time.

4. Composites

Sintering of composites is a more complex group of processes, and various materials are processed in different ways. Tungsten carbide uses tungsten and carbon powders. Pressure-heat oxidation transforms the carbon to carbide. This couples the metal powder, which remains unaltered. Glass, carbon, and metal fibers are experimentally included in metal powder sinters, to enhance properties. In some regards, the processing of carbon fiber is a sintering process. An adhesive matrix is compressed and heat activated to bond the carbon component. Metal oxide ceramics are experimentally composited with polymers such as PEEK to manufacture forms of resistive semiconductors. Sintering of composites is highly varied and can be achieved by compression, molding, and in limited cases injection molding.

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5. Glass

Various glass materials are used in sintering processes, including: ceramic glazes, silica glass, lead glass, as well as sintered glass slabs made from fused silica glass powder. Sintering of glass is generally done by compression molding.

Steps of the Sintering Process

Sintering consists of a series of steps, each of which is simple but requires great precision in control. The steps include:

1. Composition: Add and mix the required primary materials and primary coupling agents.
2. Compression: Press the powder (slurry or dry) to the required shape.
3. Heat: Heating aims to achieve the removal of the primary coupling agent and fusion of the primary material into a low-porosity whole.

Components Produced Through the Sintering Process

Components that are produced through sintering are listed below:

1. Automotive parts such as gears and actuators.
2. Electrical components such as switchgear.
3. Cutting tools of all types, for milling, drilling, and reaming.
4. Aerospace components such as fuel valve components, actuators, and turbine blades.
5. Biomedical implants such as prosthetic joints.

Benefits of Creating Your Parts With Sintering

Sintering offers a variety of benefits:

1. The process can produce highly repeatable and accurate parts.
2. The cost of establishing production is easily amortized over large production.
3. Parts can achieve great cosmetic results and require no finishing processes.
4. Non-machinable geometries for mass production are easily achieved.

Some Risks in Creating Your Parts With Sintering

Some of the risks of the sintering process including:

1. Powder consistency can vary if not well controlled, altering shrinkages or overall component properties.
2. Initial forming process controls must be precise to achieve consistent and repeatable results.
3. Post-forming &#;cure&#; processes are varied and require very tight control to precisely set shrinkage and prevent distortion.
4. The cost of establishing production is high, so if the product doesn&#;t sell this can be wasted.
5. Production process variations can result in weak and variable parts.

Xometry provides a wide range of manufacturing capabilities including CNC machining, 3D printing, injection molding, laser cutting, and sheet metal fabrication. Get your instant quote today.

Disclaimer

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry&#;s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

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