Industry Overview
Sintering is a manufacturing process in which compacted powder particles are heated to temperatures below the melting point, allowing them to bond in the solid state or with a limited amount of liquid phase. Originally developed for ceramic products, sintering has become an important process in powder metallurgy.
Sintered components can offer high toughness and strength while allowing complex shapes to be produced with limited or no machining. Applications include shock absorber pistons, belt pulleys, small helical gears, chainsaw drive gears, and automotive pump gears.
In powder metallurgy, prepared metal powders are blended in the required proportions, compacted under considerable pressure using precision tooling, and subsequently bonded or fused at elevated temperature in a furnace, generally under a protective atmosphere. The resulting finished components can achieve mechanical properties comparable in many applications to conventionally manufactured parts. This project profile deals with the manufacturing of sintered bronze bush bearings and may be useful to prospective entrepreneurs interested in powder-metallurgy-based manufacturing.
Cost Estimation
| Plant Capacity | 5 MT/Day |
|---|---|
| Land & Building (5000 sq.mt.) | Rs. 4.96 Cr |
| Plant & Machinery | Rs. 4.31 Cr |
| Working Capital for 2 Months | Rs. 2.39 Cr |
| Total Capital Investment | Rs. 12.19 Cr |
| Rate of Return | 22% |
| Break Even Point | 68% |
Content Index
- INTRODUCTION
- (A) SPIRAL WELDED PIPE
- PROPERTIES
- OIL AND GAS PIPELINE
- POWER PLANT
- WATER & SEWERAGE
- STRUCTURAL
- OTHER INDUSTRIAL
- PHYSICAL PROPERTIES OF PIPING MATERIALS
- MALLEABILITY
- DUCTILITY
- BRITTLENESS
- ELASTICITY
- CONDUCTIVITY
- CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
- B.I.S. SPECIFICATION
- MANUFACTURING PROCESS
- (A) FOR SPIRAL WELDED PIPE
- PROCESS FLOW CHART FOR SPIRAL WELDED PIPE
- MANUFACTURING PROCESS OF SPIRAL WELDED PIPE
- STEPS ARE GIVEN BELOW
- (1) PRODUCTION METHODOLOGY
- (2) GEOMETRIC MONITORING
- (3) END SHEARING, BUTT WELDING AND SIDE GUIDE ROLLERS
- (4) THE MAKING OF SPIRAL WELD PIPES
- (5) WELDING OF PIPE
- (6) CUTTING OF PIPE
- (7) TESTING OF PIPE
- ULTRA-SONIC TESTING
- X-RAY TEST AND FLUOROSCOPY
- HYDRO TESTING
- (8) FINAL INSPECTION, VISUAL CHECKING, WEIGHING AND MEASURING
- (9) COATING OF PIPE
- EXTERNAL COATING
- INTERNAL COATING
- (10) FINAL MARKING
- PLANT AND MACHINERY
- (1) UNCOILER
- (2) LAVELER
- (3) SHEAR AND WELDER
- HIGH QUALITY WELDING SEAM.
- 1. SWITCHGEAR RECTIFYING CABINET
- 2. INVERTER OUTPUT CABINET
- 3. CONNECTING OPTICAL FIBER
- 4. CIRCULATION SOFT WATER COOLING SYSTEM
- 5. CENTRAL OPERATION CONSOLE
- 6. MECHANICAL ADJUSTMENT DEVICE
- (4) ACCUMULATOR
- ACCUMULATOR
- THE HORIZONTAL SPIRAL ACCUMULATOR FOR WELDED PIPE LINE
- (5) FORMING AND SIZING SECTION
- FORMING AND SIZING MILL
- MATURE TECHNOLOGY FOR ROLLER COMPATIBILITY
- OPTIMIZED FORMING
- EDGE BENDING
- W-FORMING ON FIRST STAND
- UNIQUE MODULE ROLL (ASSEMBLY ROLL) AND JUANTIE (EDGE GRADUALLY TO CENTER) FORMING TECHNOLOGY
- (6) HF SOLID STATE WELDER
- HIGH QUALITY WELDING SEAM.
- 1. SWITCHGEAR RECTIFYING CABINET
- 2. INVERTER OUTPUT CABINET
- 3. CONNECTING OPTICAL FIBER
- 4. CIRCULATION SOFT WATER COOLING SYSTEM
- 5. CENTRAL OPERATION CONSOLE
- 6. MECHANICAL ADJUSTMENT DEVICE
- (7) ANNEALING FURNACE
- (8) FLYING SAW
- FLYING SAW
- MAIN SPECIFICATION:
- MAIN SPECIFICATION:
- FLYING SAW ALL DIGITAL CONTROL SYSTEM
- (9) FACING AND BEVELING MACHINE
- (10) STRAIGHTNER MACHINE
- (11) THREADING MACHINE
- THREADING MACHINE FEATURES:
- (12) HYDRAULIC TESTING MACHINE
- GLOBAL MARKET OF STEEL PIPES
- MARKET SEGMENTATION
- BY MATERIAL
- BY APPLICATION
- BY END-USER
- KEY MARKET PLAYERS
- STEEL PIPE INDUSTRY AT A GLANCE
- STRUCTURE AND APPLICATION OF STEEL PIPES AND TUBES INDUSTRY
- EBITDA/TONNE AND LEVERAGE ACROSS PIPE SEGMENTS/PLAYERS
- STEADY IMPROVEMENT IN CREDIT PROFILES OF BOTH SEGMENTS
- DEMAND FOR STEEL PIPES TO LOG CAGR OF 7-8%
- SAW AND SEAMLESS PIPES
- PROFITABILITY TO REBOUND FOR ERW PLAYERS, STAY HEALTHY FOR
- S&S PLAYERS
- ERW PIPES
- MOVEMENT IN OPERATING MARGINS VIS-À-VIS HR COIL PRICES
- HR COIL PRICES HAVE CORRECTED SHARPLY DUE TO EXCESS GLOBAL SUPPLY, DRIVEN BY CHINA
- SAW AND SEAMLESS
- ORDER BOOK OF S&S PIPE PLAYERS SEEN SWELLING
- CAPEX CYCLE DONE, UTILISATION UPTREND TO CONTINUE THIS FISCAL
- SAW AND SEAMLESS PIPES
- UTILISATION LEVELS HEADED NORTH
- INDIAN SAW PIPE INDUSTRY
- TABLE 1 – PRODUCT SUMMARY
- INTERNATIONAL DEMAND DRIVERS
- SEAMLESS PIPES
- SAW PIPES
- LSAW PIPES
- HSAW PIPES
- WELDED (ELECTRIC RESISTANCE WELDED (ERW) AND ELECTRIC
- FUSION WELDED
- (EFW)) PIPES
- DUCTILE IRON (DI) PIPES
- GLOBAL PIPE INDUSTRY
- DEMAND SCENARIO IN THE ENERGY SEGMENT
- ENERGY DEMAND TO GROW AT A CAGR OF 1.4%
- REPLACEMENT DEMAND FROM THE US ALSO REMAINS STRONG
- DEMAND SCENARIO IN THE WATER SEGMENT
- INDIAN PIPE INDUSTRY
- INDIAN DEMAND FOR PIPES EXPECTED TO BE STRONG
- ENERGY SEGMENT
- LOW PIPELINE PENETRATION IN INDIA PROVIDES HUGE POTENTIAL
- INCREASING SHARE OF NATURAL GAS IN ENERGY DEMAND
- WITH PETROLEUM & NATURAL GAS REGULATORY BOARD IN ACTION,
- TRUNK PIPELINES TO RECEIVE BOOST
- SWOT – INDIAN PIPE INDUSTRY
- SALIENT FEATURES OF THE INDIAN PIPE INDUSTRY
- ORDER BOOK POSITION LOOKS ROBUST
- CAPACITY UTILIZATION RANGES BETWEEN 25–60%
- HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
- STEEL PIPES MARKET OVERVIEW
- MARKET SIZE & FORECAST
- GROWTH DRIVERS & CHALLENGES
- SUPPLIERS OF RAW MATERIALS
- M.S STRIP COILS
- WELDING ELECTRODES
- PICKLING CHEMICALS
- PACKING MATERIALS
- SUPPLIERS OF PLANT AND EQUIPMENTS
- TUBE MILL
- SUBMERGED ARC WELDING EQUIPMENT
- THREE ROLLER BENDING MACHINE
- PLATE BENDING MACHINE
- PIPE CUTTING MACHINE
- PIPE STRAIGHTENING MACHINE
- HYDROTESTING EQUIPMENT
- BEND TESTING EQUIPMENT
- POWDER COATING MACHINE
- SUPPLIERS OF HIGH FREQUENCY INDUCTION WELDER
- EOT CRANE
- POWER TRANSFORMER
- ELECTRICAL PANEL
- ELECTRIC MOTOR
- COOLING TOWER
- EFFLUENT TREATMENT PLANT (ETP PLANT)
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSORS
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
- SHOT BLASTING MACHINE
- JIGS AND FIXTURE
- SUBMERSIBLE WATER PUMP
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Sintering is a powder-metallurgy process in which compacted powder is heated below its melting point to bond the particles together. The process produces a solid component through diffusion and, depending on the material and process conditions, may involve a limited liquid phase. Sintering follows powder preparation and compaction and is used to manufacture components with controlled dimensions and complex shapes. It can reduce the need for extensive machining and is widely used for industrial and engineering components.
Sintered metal components can provide good strength, toughness, dimensional consistency, and design flexibility. Because the powder is compacted before sintering, components with relatively complex geometries can often be produced close to their final shape. This near-net-shape capability can reduce material waste and machining requirements. The process is particularly useful for high-volume manufacturing where repeatability and controlled material properties are important.
A sintered bronze bush bearing is a bearing component manufactured by compacting bronze-based powder and subsequently sintering it. Such bushings are used to provide a bearing surface between moving components while supporting controlled friction and wear characteristics. Powder metallurgy allows the bearing to be produced with consistent geometry and material properties. Depending on the design and application, sintered bronze bearings can also be manufactured with controlled porosity for specific lubrication requirements.
The main stages generally include powder selection and preparation, blending, compaction, sintering, and subsequent finishing or inspection. The powder is blended to obtain the required composition and characteristics before being pressed in suitable tooling to form a green compact. The compact is then heated under controlled atmospheric conditions at a temperature below the melting point. Depending on the product, additional operations such as sizing, machining, impregnation, surface treatment, or quality inspection may follow.
Compaction is important because it transforms loose metal powder into a shaped green compact with sufficient integrity for handling and subsequent sintering. Pressure applied through precision tooling determines the basic geometry and influences the density distribution of the compact. Proper powder preparation, tooling design, lubrication, and pressing conditions are important for achieving consistent results. Effective compaction also supports dimensional control and helps the sintering stage produce components with the intended mechanical and physical characteristics.
Sintering can be used to manufacture a wide range of powder-metallurgy components, including gears, pulleys, bushings, pistons, and other precision engineering parts. The report specifically identifies shock absorber pistons, belt pulleys, small helical gears, chainsaw drive gears, and automotive pump gears as examples. Product selection depends on material properties, required geometry, production volume, dimensional tolerances, and the performance requirements of the final component.
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