Can Fine Iron Powder Be Compressed into a Solid Puck Without Heat or Binders?

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SUMMARY

Compressing fine iron powder, specifically with a particle size of about 30 microns, into a solid puck without heat or binders is feasible but requires significant pressure. The process involves overcoming the surface layer of iron oxide that forms due to the powder's affinity for atmospheric moisture. Utilizing a lubricant is essential to facilitate cold compaction and achieve effective cold welding of the iron particles. The pressure required for this process will exceed initial expectations.

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  • Understanding of powder metallurgy principles
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  • Familiarity with the properties of fine iron powder
  • Experience with compaction techniques and equipment
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  • Investigate the use of lubricants in cold compaction processes
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I was just curious if it would be possible to compress fine iron powder into a solid puck without applying any heat or binding chemicals, etc. I'm guessing it would take several tonnes of force?

Particle size of powder: about 30 microns
 
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Look up 'sintering' or 'powder metallurgy'. Various metallic and ceramic products are made by compressing powdered raw material.
 
Thanks, I wasn't sure where to start looking. I guess my google searches were too specific.
 
Thirty microns is quite fine for iron powder. You would probably need a lubricant to to cold compact such a fine powder in practice. This is because fine iron has quite an affinity for water vapour from the atmosphere and the resultant surface layer of iron oxide will take quite a bit of pressure to break up this oxide layer so that cold welding between the underlying iron can occur.

Yes, you can do it, but the required pressure will be higher than you think.

In diamond setting, they compact very fine cobalt powder under very high pressure and then sinter it to get to near full density
 

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