---
title: FAQs | PMES PM
description: Get all the top FAQ's here from PMES PM.  Learn about our high performance powered metals and more!
image: https://www.psmindustries.com/hubfs/polyalloys-images/227-977373-edited.jpg
---

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# FAQs & Resources

## Frequently Asked Questions About Powdered Metal Manufacturing

[fa icon="plus-square"] How are powdered metals produced?

There are a variety of ways that powdered metals (the raw material for PM parts) are produced, but the predominate method is atomization.  A good explanation of the atomization process can be found in Powdered Metallurgy Review Magazine:

*“Atomisation involves the disintegration of a thin stream of molten metal through the impingement of high energy jets of a fluid (liquid or gas). Water is the most commonly used liquid in atomisation.*

*Water atomised iron powders also have irregular particle shape and therefore good green strength. Unlike sponge iron, the individual powder particles do not contain internal porosity and, because of extensive development of the annealing process, have superior compressibility (see section on Forming processes). Water atomised powders are therefore the material of choice where high green density is sought in PM structural parts.”*

For more information on the production of powdered metals please see:

[http://www.pm-review.com/introduction-to-powder-metallurgy/powder-production-technologies/](http://www.pm-review.com/introduction-to-powder-metallurgy/powder-production-technologies/)

[fa icon="plus-square"] What kind of metals can be made using the PM process?

An extremely wide array of metals can be made through the PM process. In principle, the technique is applicable to all metals that can be melted and is used commercially for the production of iron; copper; alloy steels; brass; bronze; low-melting-point metals such as aluminum, tin, lead, zinc, and cadmium; and, in selected instances, tungsten, titanium, rhenium, and other high-melting-point materials.

[fa icon="plus-square"] How strong is a PM part vs. a wrought part?

With proper engineering and material selection, PM material properties can match up well with your needs.  Please [see our materials selector](https://www.psmindustries.com/pacific-sintered-metals/high-performance-powder-metal-processes-materials) to understand the strength, elongation and other engineering data that will help you choose the right material for your application.

[fa icon="plus-square"] How do you design for PM?

While the design of PM is very flexible, it does require that the compact has no undercuts and is able to be ejected from a die cavity.  We suggest reviewing our industry website [https://www.pickpm.com/design-resource-center/design-considerations/](https://www.pickpm.com/design-resource-center/design-considerations/) to help you tailor your component design to the PM process.  Or feel free to [contact our sales team](https://www.psmindustries.com/pmes-pm/contact-pm-engineered-solutions-connecticut) for help with the design process.

[fa icon="plus-square"] How much does tooling cost for the PM process?

PM tooling can cost as little as a few thousand dollars for a very simple shape to $30,000 for large and complex part with many levels.  Typically tooling costs between $5,000 and $15,000 for most parts that are tooled in PM.

[Reach out and talk to a member of our sales team](https://www.psmindustries.com/pmes-pm/contact-pm-engineered-solutions-connecticut) to help evaluate your component design to determine its feasibility and tooling cost.

[fa icon="plus-square"] What is a typical run size that fits the PM process?

We tool parts for as little as 500 pieces annually and have some parts that we run millions each year.  Each of our plants is set up to handle either “short-run PM”, “normal PM” or “high-volume PM”.

We would define run sizes as follows:

**Short-run PM** → 500 to 10,000 pieces

**Normal-run PM** → 10,000 to 100,000 pieces

**High-volume PM** → 100,000 to 10,000,000 pieces

[Talk to our sales team](https://www.psmindustries.com/pmes-pm/contact-pm-engineered-solutions-connecticut) to help determine which of our PM operations is the best fit for you.

[fa icon="plus-square"] How is copper infiltration used in the PM process?

Copper infiltration is a method that is commonly used in PM to fill the open porosity in a steel PM compact in an effort to either increase the strength of the part or to seal porosity for a pneumatic or hydraulic application (or both).  An article in Industrial Heating Magazine has a good technical definition of the infiltration process:

*“Infiltration is basically defined as "a process of filling the pores of a sintered or unsintered compact with a metal or alloy of a lower melting point." In the particular case of copper infiltrated iron and steel compacts, the base iron matrix, or skeleton, is heated in contact with the copper alloy to a temperature above the melting point of the copper, normally within the range of 2000¯ to 2100¯F (1095¯ to 1150¯C). Through capillary action, the molten copper alloy is drawn into the interconnected pores of the skeleton and ideally fills the entire pore volume”*

For further information on copper infiltration, you can read more through this link:

[https://www.industrialheating.com/articles/83856-a-description-of-the-copper-infiltration-process-used-in-iron-based-p-m-parts](https://www.industrialheating.com/articles/83856-a-description-of-the-copper-infiltration-process-used-in-iron-based-p-m-parts)

[fa icon="plus-square"] Can you do secondary machining on a PM part?

PM parts are readily and regularly machined with success.  If you plan to machine your PM component, it would be beneficial to discuss this with our sales team.  Typically we will plan to add manganese sulfide (MnS), plastic impregnation or copper infiltration to the process if machining is required.

If you would like more information, [please see this attached white paper on machining PM](https://www.psmindustries.com/hubfs/Machining%20PM.pdf). 

[fa icon="plus-square"] What kind of tolerances can be maintained in the PM process?

PM is known for its ability to hold tight tolerances and to maintain them over the long run.  Typically in the direction of pressing on a pressed and sintered compact we can hold +/-0.004” (0.1mm) and +/-0.2% in the die direction.  Please call our sales team to discuss more in detail for your application.

For additional information, [please read this industry white paper on PM tolerances](https://www.psmindustries.com/hubfs/PM%20Tolerances.pdf).

[fa icon="plus-square"] Why is a lubricant added to powdered metals before molding a part?

Typically, between 0.5 and 1.0% (weight) of PM raw material is a wax-based lubricant that aids in the molding and ejection of a preform to reduce tool wear.  During the early stages of sintering (the step after molding that fuses the powder particles together), the lubricant is burned away.

[Here is an article from Metal Powder Review Magazine](https://www.psmindustries.com/hubfs/The%20New%20Benefits%20of%20Binder%20Lubricants.pdf) that discusses recent developments in PM lubricant technology.

[fa icon="plus-square"] What size parts can be made by the PM process?

The PM process is very versatile and regularly produces components as small as a grain of sand and as large as a basketball.  PSM has concentrated the size of parts it produces by operation and has typically making parts as small as a bb and as big as a softball.

[fa icon="plus-square"] What are the advantages of the PM process over other metalworking processes?

The on-going growth of PM over other more traditional metalworking techniques like casting, machining or stamping is the unique combination of advantages that it offers, like:

1. Low part cost
2. Shape complexity
3. Tight and uniform tolerance control
4. Excellent surface finishes
5. Relatively inexpensive tooling
6. Ability to process unique materials
7. Low process energy or material waste
8. Environmentally clean processing

Here’s some additional information about the advantages of PM over other metalworking techniques from the European Powdered Metal Association:

[https://www.epma.com/powder-metallurgy-economic-advantages](https://www.epma.com/powder-metallurgy-economic-advantages)

## **Economic Advantages**

The growth of the P/M industry during the past few decades is largely attributable to the cost savings associated with net (or near-net) shape processing compared to other metalworking methods, such as casting or forging. In some cases, the conversion of a cast or wrought component to powder metal provides a cost savings of 40% or higher.  
PM typically uses more than 97% of the starting raw material in the finished part and is specially suited to high volume components production requirements.

**There are two principal reasons for using a powder metallurgy product:**

1. Cost savings compared with alternative processes, and
2. Unique properties attainable only by the PM route

In the automotive sector, which consumes about 80% of structural PM part production, the reason for choosing PM is, in the majority of cases, an economic one.  
PM process enables products to be made that are capable of absorbing up to 35% of selected fluids.

**Why then is PM more cost effective?**

Better material utilisation with close dimensional tolerances. Conventional metal forming or shaping processes, against which PM competes, generally involve significant machining operations from bar stock or from forged or cast blanks.

These machining operations can be costly and are wasteful of material and energy.This is illustrated in the figure below which shows that material utilisation in excess of 95% can be achieved with close dimensional tolerances.

Raw material utilisation and energy requirements of various manufacturing processes.

This is a comparison between various manufacturing processes (Casting, Cold or Warm Extrusion, Hot Drop Forging, and Machining Processes) and PM sintering for a production of notch segments for truck transmission.

**The PM process has:**

- the highest raw material utilisation (over 95%)
- and the lowest energy requirement per Kg of finished part
- comparing with the other manufacturing processes

![Manufacturing processes raw material](https://www.psmindustries.com/hs-fs/hubfs/pacific-sintered-metals/Screen%20Shot%202018-04-15%20at%2010.59.20%20AM.png?width=521&height=384&name=Screen%20Shot%202018-04-15%20at%2010.59.20%20AM.png)

**Energy Savings**

The energy savings alone contribute significantly to the economic advantage offered by PM..

An example is given below for a notch segment used in a truck transmission, where PM consumes only around 43% of the energy compared with forging and machining and the number of process steps has been greatly reduced. .

**Comparison of the PM Process and Forging and Machining (energy requirements and number of process steps)**

This is an example for a notch segment used in a truck transmission, where:

- PM consumes only around 43% of the energy compared with forging and machining, and
- the number of process steps has been greatly reduced

**PM process:**

**![PM Process](https://www.psmindustries.com/hs-fs/hubfs/pacific-sintered-metals/Screen%20Shot%202018-04-15%20at%2010.59.37%20AM.png?width=568&height=330&name=Screen%20Shot%202018-04-15%20at%2010.59.37%20AM.png)**

**Forging and machining:**

**![forging and machining](https://www.psmindustries.com/hs-fs/hubfs/pacific-sintered-metals/Screen%20Shot%202018-04-15%20at%2010.59.56%20AM.png?width=561&height=479&name=Screen%20Shot%202018-04-15%20at%2010.59.56%20AM.png)**

**Cost Comparison between PM and Forging:**

**![comparison between powder metal and forging](https://www.psmindustries.com/hs-fs/hubfs/pacific-sintered-metals/Screen%20Shot%202018-04-15%20at%2011.00.09%20AM.png?width=514&height=357&name=Screen%20Shot%202018-04-15%20at%2011.00.09%20AM.png)**

For further information, here is an article from Powdered Metallurgy Review Magazine that highlights PM’s advantages:

[http://www.pm-review.com/introduction-to-powder-metallurgy/why-powder-metallurgy/](http://www.pm-review.com/introduction-to-powder-metallurgy/why-powder-metallurgy/)

[fa icon="plus-square"] Is tooling required to make a PM part?

To be able to mold a PM compact, tooling is required. Typically a fill of powdered metal of between 2 and 3 times the final part thickness is required.  Tooling must withstand molding pressures of between 30 and 50 tons per square inch, so they are usually made from high grade tool steels and tungsten carbides.

[fa icon="plus-square"] How long does it take to tool a PM part?

Tool design, tool build and first article production lead-times can range from as low as 6 weeks for a very simple PM part to 12 weeks for a complex one.  If a PPAP process is required, we would usually add one week to the lead-time.

[Reach out and talk to a member of our sales team](https://www.psmindustries.com/pmes-pm/contact-pm-engineered-solutions-connecticut) to help evaluate your component design to determine its feasibility and tooling cost.

[fa icon="plus-square"] What does the word “sinter” mean?

From Powdered Metal Review Magazine:

*“Sintering is a heat treatment applied to a powder compact in order to impart strength and integrity. The temperature used for sintering is below the melting point of the major constituent of the Powder Metallurgy material.*

*After compaction, neighboring powder particles are held together by cold welds, which give the compact sufficient “green strength” to be handled. At sintering temperature, diffusion processes cause necks to form and grow at these contact points.”*

If you would like to read more from this article, here is the link:

[http://www.pm-review.com/introduction-to-powder-metallurgy/sintering-in-the-powder-metallurgy-process/](http://www.pm-review.com/introduction-to-powder-metallurgy/sintering-in-the-powder-metallurgy-process/)

[fa icon="plus-square"] What is the plastic impregnation process for the PM process?

Plastic impregnation is a method used to fill the interconnected porosity of a PM compact with a polyester resin to enhance machinability, allow plating and to create a pressure-tight part for a sealing application.

Here is a good article from Modern Machine Shop Magazine which discusses the benefits of plastic impregnation for a PM component:

[https://www.mmsonline.com/articles/increased-machinability-and-improved-finish-of-powdered-metal-parts](https://www.mmsonline.com/articles/increased-machinability-and-improved-finish-of-powdered-metal-parts)

[fa icon="plus-square"] Can you plate a PM part?

Yes, PM parts respond well to almost all conventional plating techniques once the open porosity of the component has been sealed by plastic impregnation or copper infiltration of the inherent porosity of the process.

[fa icon="plus-square"] Can you heat treat a PM part?

 In short, yes! In most cases, a PM part will use the same procedures used to heat treat wrought materials of the same compositions.  Please refer to the attached white paper:  ["Powder metallurgy materials can be heat treated with great success"](https://www.psmindustries.com/hubfs/Heat%20Treating%20PM.pdf) if you have additional questions.

## Resources

#### Why Choose PM over other processes?

#### Conventional PM Technical Overview

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      "text" : "There are a variety of ways that powdered metals (the raw material for PM parts) are produced, but the predominate method is atomization. A good explanation of the atomization process can be found in Powdered Metallurgy Review Magazine:\n\n“Atomisation involves the disintegration of a thin stream of molten metal through the impingement of high energy jets of a fluid (liquid or gas). Water is the most commonly used liquid in atomisation.\n\nWater atomised iron powders also have irregular particle shape and therefore good green strength. Unlike sponge iron, the individual powder particles do not contain internal porosity and, because of extensive development of the annealing process, have superior compressibility (see section on Forming processes). Water atomised powders are therefore the material of choice where high green density is sought in PM structural parts.”\n\nFor more information on the production of powdered metals please see:\nhttp://www.pm-review.com/introduction-to-powder-metallurgy/powder-production-technologies/"
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