Date of Award

11-2010

Degree Type

Thesis

Degree Name

Master of Applied Science (MASc)

Department

Mechanical Engineering

Supervisor

Mukesh K. Jain

Language

English

Abstract

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The aim of this research is to enhance performance and durability of the final PM component by improving spatial density homogeneity at die filling stage of powder metallurgy process. In this research, powder die filling processes has been studied using a novel laboratory experimental set-up, with a ring-shaped die, for assessing die fill characteristics of thin, high precision components of interest to Gates Canada.

In this investigation, usefulness of incorporating a perforated plate at the bottom of the feed shoe to improve the density uniformity in the filling condition is assessed. With this arrangement, flow and distribution of powder during the delivery stage is monitored. The powder flow pattern observed through the transparent window is utilized for obtaining full-field displacement data using an optical measurement technique. In addition to the above, several powder flow characteristics during die filling have been studied through a series of high-speed camera recordings. The role of shoe speed, and powder properties in the development of density gradient have been experimentally assessed. A series of full-scale experiments with coloured salt as a powder medium to mimic the iron powder flow have been conducted to understand flow patterns, and segregation of powder during the filling process.

Further, a novel method of density measurement of the part in die-fill condition by heating iron powder with a polymeric resin is explored. Qualitative density data obtained from the die filling experiments, and subsequent porosity data from powder sintering in the die have been compared, to understand the reasons for density gradient in the die-cavity.

McMaster University Library

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