Sintered Product Manufacturing Process

Sintered Product Manufacturing Process

Raw Material

The raw material used for manufacture of Sintered Bearings and Parts are highly compressible and soft metal proders namely Copper Powder, Tin Powder, Pre-Alloyed Bronze Powder, Iron Powder as son on. These raw materials adhere to high quality standards with respect to mesh size, structure of powder, level of impurities and hydrogen loss.

Blending

These powders are homogeneously blended in various types of double cone and Y cone blenders with suitable powder lubricants to assure homogeneity and no powder fracture and stress generation.

Compaction

The loose metal powders are molded into a near net definite and particular shape and size. This process is called Compaction which is carried out on various types of highly advanced, modern Mechanical and Hydraulic Presses.

The flexibility of manufacturing a plain bushing to a complex gear for a business machine or a rotor pump for a lawn mover to a Value plate for an air conditioner is entirely dependant upto Compaction Presses.

Tool Room

We have dedicated tool room facility to manufacture various types of tools in-house. The tool room provides an enternal backbone to the ever changing product range requirement. All tools are designed in house and operations carried out under strict control and supervision to ensure right quality of the product.

Sintering

The compacted / green products obtained from the presses are fragile and powder compacted under mechanical loads needs to be bonded together with metallurgical bond.

The components are passed through a Continuous, mesh belt type, electrically heated, controlled atmosphere sintering furnace.

The components are placed on the charging end of the sintering furnace at the room temperature. The material is sintered at temperature ranging from 800 C to 1120 C for a time span of 25 min to 45 min depending upon the alloy of the component.

The entire atmosphere inside the furnace is controlled with no presence of oxygen. The material heats and retains at the desired temperature for the time required before it cools down to room temperature, all under specifically controlled atmosphere, time and temperature.

The entire process is controlled using various controls on Sintering furnace backed with Controlled Atmosphere generator, de-humidizers and flow control rotometers.

The product thus obtained has adequate strength and porosity to carry out further operation.

Finishing Operation

Deburring, Sizing, Drilling, Oil Impregnation and as required Steam Impregnation is carried out in house.

Steam Impregnation

Iron components may be subjected to steam impregnation upon requirement of components.

Steam impregnation process involves subjecting Sintered Ferrous Components maintained above 550 C to super heated steam. This process imparts a shiny blue-black film of Fe3O4 on the components. The major advantage of steam impregnation is as follows

• The blue-black film generated on the component makes it resistant to rust.
• The process of steam impregnation increases wear resistance of the components.
• The steam impregnated components shows increase in hardness values on the surface of the component whereas the core of the component maintains its initial hardness values.
• The porosity of the components gets closed making the Sintered Components usable where high pressure fluids or gas is used, for example pistons and high end rod guides for shock absorber parts.
• The blue black film generated on the components adds aesthetic value of the component.