Near-Net Shape Fabrication Technologies Utilizing Powder Metallurgy and

Particulate Materials

Alan LawleyDepartment of Materials Engineering

Drexel UniversityPhiladelphia, PA 19104

FABRICATION OF FPC’S

n Is There a Role for Powder Processing?n Intrinsic Capabilities of Powder Processingn Powdersn Powder Processing Technologiesn Joining of Powder Metal Componentsn Is There a Role for Powder Processing?

INTRINSIC CAPABILITIES OF POWDER PROCESSING

n Compositional Flexibilityn Chemical/Microstructural Homogeneityn Fine-Scale Microstructuresn Net or Near-Net Shape Capability

Ferrous P/M MaterialsDensity

Composition Microstructure

MECHANICALMECHANICAL

PROPERTIESPROPERTIES

Alloying Methods

Admixed Partially Alloyed

Prealloyed Hybrid

POWDER PROCESSING TECHNOLOGIES

n Press + Sintern Powder Injection Moldingn Powder Forging/Extrusionn Hot Isostatic Pressingn Spray Forming

Powder Forging

Hot Isostatic PressingProcess Schematic

SPRAY FORMING

JOINING OF POWDER METAL COMPONENTS

n Weldingn Sinter-Brazingn Brazingn Soldering

WELDING

Ferrous Powder Metal Automotive Components- Fusion Welding (Gas Metal Arc)- High Speed Pulse Welding

SOLDERINGNon Ferrous Metals/Alloys – Electrical Connections

Between Discrete Electronic Devices and Circuit Boards- No Clean, Water Soluble, Rosin-Mildly Activated

Soldering- Reflow Soldering- Pb Free Solder Alloys

Filler Metal MPt <400OC

SINTER BRAZING

Ferrous Powder Metal Automotive Components

- Concurrent Sintering and Brazing

BRAZING

Ferrous and Non Ferrous Alloys –Automotive, Appliance, Recreational, Electronics

- Torch Brazing- Furnace Brazing

Filler Metal MPt >400oC