Powder Metallurgy Consolidation Processes

Powder metallurgy consolidation processes use fine metal powders or particulate materials as the raw material. These processes require consolidation and provide varied benefits to the finished part depending on the consolidation process.

The two principal metal-forming consolidation process categories are press-and-sinter (also known as conventional powder metallurgy) and near-fully dense processes.

For more detailed explanations than what you will read below, there are several PM educational videos available on this website, including specific videos on hot isostatic pressing, metal injection molding, and an introduction to powder metallurgy.

Near Fully Dense Processes

The powder metallurgy process has expanded into the production of near-fully dense materials and parts, with residual porosity often being less than 1%. These consolidation processes use different compacting methods and may involve greater emphasis on high-alloy materials and enhanced sintering techniques.

These processes include:

• Metal injection molding (Visit the Metal Injection Molding Association for details)
• Cold and hot isostatic pressing (Visit the Isostatic Pressing Association for details)
• Metal additive manufacturing (Visit the Association for Metal Additive Manufacturing for details)
• Powder forging

Powder Metallurgy Consolidation Processes vs. Other Metal-Forming Processes

There are advantages of using powder metallurgy over other metal-forming processes; however, it's important to understand that there are various advantages to using one process over another. Study the resources on this site and consult with a PM parts fabricator to discover the right metal-forming process for your component.