Artificial Intelligence in Engineering 14 (2000) 39–44

www.elsevier.com/locate/aieng

A neural network approach for selection of powder metallurgy materials

and process parameters
R.P. Cherian, L.N. Smith, P.S. Midha*
Faculty of Engineering, University of the West of England, Bristol BS16 1QY, UK
Received 1 September 1998

Abstract
The artificial neural network (NN) methodology presented in this paper has been developed for selection of powder and process parameters
for Powder Metallurgy (PM) part manufacture. This methodology differs from the statistical modelling of mechanical properties in that it is
not necessary to make assumptions regarding the form of the functions relating input and output variables. Employment of a NN approach
allows specification of multiple input criterion, and generation of multiple output recommendations. The inputs comprise the required
mechanical properties for the PM material. The system employs this data within the NN in order to recommend suitable metal powder
compositions and process settings. Comparison of predicted and experimental PM materials data has confirmed the accuracy of the NN
approach, for predicting the materials and process settings needed for attainment of required process outcomes. q 2000 Elsevier Science Ltd.
All rights reserved.
Keywords: Powder metallurgy; Material and process parameter selection; Neural networks

1. Introduction
It is well known that part manufacture using PM technol-
ogy can lead to significant material and energy savings in
some cases. Appreciation of the potential of PM technology
for a given application often takes place after a part has been
designed for manufacture by an alternative technology. In
fact consideration of PM often does not occur until the part
has been in conventional production for a considerable
period of time. Even in cases where a part is identified for
manufacture using PM process, selection of material and
process parameters require inputs from a number of experts
in the field. Unlike wrought parts, design specifications
determine the process parameters and type of powder mate-
rial to be used in producing a PM part. One of the reasons for
not designing a part for PM in the first instance is the lack of
suitable guidelines in the selection of appropriate metal
powder grade and process parameters.
Implementation of ‘design for manufacture’ methods in
PM industry requires systems that can store material and
process related information in an easily usable form. This
information can then be used at the design stage to select
material, verify the properties attainable through the
* Corresponding author. Fax: 144-117-9762150.
E-mail address: sagar2.midha@uwe.ac.uk (P.S. Midha).
process, cost implications etc. before part designs are final-
ised. Knowledge Based Systems (KBS) that are currently
used in a number of design and manufacture applications
can also be used to support closer integration of PM design/
manufacture functions.
The development of a KBS for analysis of design geome-
try, materials selection, and PM process parameters has
been the focus of the research being carried out by the
authors, and some work has already been reported [1,2].
Materials selection is particularly suited to application of
KBS methods, since PM powder and part manufacturers
have generated large amounts of empirical data which
could form the basis of production rules and/or process
models for the KBS. Thus, the KBS can encapsulate the
knowledge and experience of industry experts and can assist
the design and manufacturing engineers, customers, suppli-
ers and less experienced engineers, in PM design and
production decisions. Previous attempts to develop materi-
als selection modules have employed regression analysis for
the powder related data [1–4]. The resulting relationships
have provided reasonably accurate predictions of, for exam-
ple, the tensile strength for various densities of PM iron.
However for somewhat more complex cases involving, for
example, non-standard compaction and sintering condi-
tions, simple statistical methods for data modelling have

0954-1810/00/$ - see front matter q 2000 Elsevier Science Ltd. All rights reserved.
PII: S0954-181 0(99)00026-6
40 R.P. Cherian et al. / Artificial Intelligence in Engineering 14 (2000) 39–44
been found to be unsatisfactory. The reasons for this include
the following:
• The mechanical properties of PM materials depend on
the compaction pressure, sintering temperature and atmo-
sphere, chemical composition of the powder and addi-
tives in addition to the physical properties of the powder
material used. Since the effects of these factors may
not be linear, and are usually inter-related, statistical
methods such as linear regression are limited in their
ability to predict the resulting process outcomes.
• Although large amounts of PM data are in existence, appre-
ciable scatter, or noise, is observed. Also, it may be possible
to use a number of alternative input permutations for produ-
cing a PM part for a given set of mechanical properties.
• Finally, substantial gaps are present in the available data.
Statistical methods such as regression analysis are not parti-
cularly suited to modelling data with these types of
characteristics [5].
1.1. Adoption of a neural network approach
The above considerations have led to the identification of
Neural Networks (NN) as being particularly suitable for
modelling the mechanical properties of PM materials
under various processing conditions. Consider, for example,
the large number of system inputs associated with the PM
process. In addition to the large variation in sintering and
compaction conditions that can be employed, the addition of
small amounts of alloying elements to a metal powder can
have a profound effect upon the final mechanical properties.
When employing a NN approach, it is relatively easy to
incorporate a large number of system inputs to accommo-
date these effects. Since the modelling is directly incor-
porated within the weights of the NN connections, any
non-linearity or inter-dependence within the relationships
is necessarily incorporated within the output predictions.
This paper reports the work on a NN based system which
has been developed to assist with selection of iron powders
for PM component production. Predictions made as a result
of NN modelling of the test data were found to be in reason-
able agreement with actual results for plain iron powder
(Hoganas NC100.24). Table 1 presents the predicted and
the actual results.
It is intended that the power and flexibility of the NN be
combined with other knowledge processing methods includ-
ing rule based inferencing, theoretical and empirical model-
ling, and case-based reasoning for the development of an
advisory system for the application of PM technology for
the design and manufacture of parts.
2. A neural network for PM materials selection
2.1. Process modelling using statistical tools
The large amount of raw experimental data available to
PM part designers has traditionally been used for powder
selection through employment of modern Structured Query
Language (SQL) databases [6,7]. Such systems, although
useful, in many ways contribute little to our understanding
of the process, and are not flexible enough to incorporate the
effect of variation in processing parameters and alloy
additions, on the final mechanical properties.
A number of researchers have identified empirical rela-
tionships between process outcomes such as sintered
density, and the mechanical properties of the final PM
part material [3,4,8–10]. These relationships were arrived
at through multiple regression analysis of experimental
results. Although observed behaviour could, to some extent,
be explained by the models, the relationships generally
involve considerable simplification of the process in terms
of the number of parameters that can be modelled. The
fundamental limitations of multiple regression techniques
for development of complex non-linear relationships
between interacting variables (as is found in PM) limit the
development of a comprehensive model using this
technique.
In reality, materials for PM products need to satisfy a
number of mechanical requirements (i.e. yield strength, fati-
gue, elongation, etc.). Therefore separate regression equa-
tions would have to be developed to correlate these
properties to relevant process variables. Effective utilisation
of statistical techniques for such modelling requires access
to very large amounts of wide ranging empirical data. The
time and expense associated with provision of such large
amounts of experimental data provides an incentive for
investigations into alternative sophisticated modelling tech-
niques. One such technique is the modelling of PM materi-
als behaviour, through the application of a suitable NN.
2.2. PM modelling using artificial NNs
In recent years a considerable research effort has gone
into the development of NN data analysis, function approx-
imation, sensor processing, and control [11,12]. Signifi-
cantly, their ability to perform complex non-linear
mappings can be used for approximating multiple input,
multiple output relationships. The modelling problem in
PM can be thought of as a continuous non-linear mapping
from ‘n-dimensional property space’ to ‘m-dimensional
process parameter space’.
Neural Networks or Artificial Neural Networks (ANN)
operate by simulating the ability of biological neural
systems to perform complex decision making tasks, without
any prior programming. Though they are far simpler than
biological systems, NNs learn from examples and function
in a similar way to animals, which learn to respond to
various stimuli in their environment. NNs are used in a
number of applications where the observed phenomenon
is either too complicated to model using conventional
tools or is not clearly understood. Such applications involve
classification and function mapping/approximation
Table 1
Required mechanical properties and the corresponding process settings—predicted by the NN model and as obtained as a result of the laboratory tests. Units employed are: tensile strength (MPa), hard–hardness

R.P. Cherian et al. / Artificial Intelligence in Engineering 14 (2000) 39–44

(HV10), compact–compaction pressure (MPa), sintering temperature (8C), sintered density (gm cm 23)

Required mechanical properties NN predicted process settings Experimental data from laboratory tests

Ten. Stren. % Elongn. Hard. (HV) Sint.Den. Compact. Sint.Temp. % Carbon % Copper Sint.Den. Compact. Sint.Temp. % Carbon % Copper

169 4.8 51 6.1496 290.60 1120 0.0001 1.9294 6.2 300 1120 0 2
297 10.2 92 7.0522 699.40 1120 0 2.0416 7 700 1120 0 2
250 7.8 74 6.7515 495.30 1120 0.0004 2.2794 6.71 500 1120 0 2
195 2.8 57 6.1469 294.56 1120 0.0017 4.0729 6.1 300 1120 0 4
275 3.8 76.5 6.6311 509.06 1120 0.008 4.0886 6.64 500 1120 0 4
320 4.8 90 6.8692 681.30 1120 0.0008 3.9044 6.88 700 1120 0 4
380 2.2 110 6.2454 292.91 1120 0.6003 1.8953 6.18 300 1120 0.6 2
479 2.6 138 6.6843 460.51 1120 0.6329 2.0756 6.75 500 1120 0.6 2
510 3.3 171 7.0472 698.76 1120 0.6156 1.8864 6.96 700 1120 0.6 2
215 3.6 75 6.062 264.65 1120 0.2079 2.0634 6.07 300 1120 0.2 2
293 4.6 97 6.7665 521.38 1120 0.2299 1.8657 6.73 500 1120 0.2 2
316 5.85 112 6.9823 690.72 1120 0.2176 1.6502 6.97 700 1120 0.2 2
225 3.6 90 6.0783 286.03 1120 0.7731 0.0005 6.14 300 1120 0.8 0
335 4.25 119 6.7448 503.98 1120 0.7526 0.0173 6.71 500 1120 0.8 0
375 4.6 135 6.9069 665.45 1120 0.7924 0.0007 6.94 700 1120 0.8 0
185 4.2 76 6.1617 288.07 1120 0.4716 0.0249 6.12 300 1120 0.5 0
275 4.8 100 6.7137 498.93 1120 0.4979 0.0337 6.72 500 1120 0.5 0
302 5.2 115 6.9132 655.93 1120 0.6667 0.0092 6.96 700 1120 0.5 0
139 12.75 36 6.2277 309.73 1205 0 0.0005 6.2 300 1220 0 0

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42 R.P. Cherian et al. / Artificial Intelligence in Engineering 14 (2000) 39–44
problems, which exhibit a degree of imprecision. The ‘crisp’
rules of a conventional expert system cannot be easily
applied to solution of these problems. However, a NN can
be trained iteratively from examples to learn and represent
the complex relationships represented within the data. In
fact the general applicability of the technique has been
demonstrated by the proof that feedforward networks with
a single hidden layer, having sufficient number of neurones,
using threshold or sigmoid activation function, are universal
approximators [13].
Many successful applications using NNs for predicting
material properties are reported in the literature [6,7,14–
16]. For example, Cool et al. [16] represent the yield and
ultimate tensile strength of steel weld deposits as a function
of numerous variables. Here the NN complexity was
controlled using Bayesian framework developed by
MacKay [17]. Regarding Powder Metallurgy modelling
published results focus on predicting mechanical properties
as a function of process parameters, such as sintered density
and alloy composition. However, PM design requirements
are ‘property driven’, i.e. the designer works from a required
property to find a suitable material. It was therefore consid-
ered necessary to relate processing parameters and powder
selection to mechanical properties. Such an approach
presents a number of challenges, such as the problems asso-
ciated with mapping a single output to multiple input possi-
bilities. This problem is particularly relevant to PM, since
the same mechanical property combinations can be attained
through different process/alloy parameter combinations.
However, by carefully selecting the training and test data
for the NN, this problem can be overcome.
The NN described here utilises training data comprising
200 sets of data taken from CASIP [18], for water atomised
plain iron, with apparent density 2.4 g/cc and a mean parti-
cle size of 100 mm. Three mechanical property combina-
tions (tensile strength, elongation, and hardness) were
chosen as the input to network (three inputs). Network
outputs were sintered density, compaction pressure, sinter-
ing temperature, sintering atmosphere and percent carbon
and copper additions (six outputs). Sintering time was
30 min in either a dissociated ammonia, or endothermic
atmosphere, for all the training data.
Before training the network the training data was normal-
ised in the range of 21 and 11:
xn ˆ ‰2 p …x 2 xmin †=…xmax 2 xmin †Š 2 1 …
where xn is the normalised value for the variable, and xmin
and xmax are the minimum and maximum of each variable
‘x’.
Different combinations of the number of layers and
neurones were tried, and a network with two hidden layers
(15 neurones in the first layer and 19 neurones in the second
layer) was found to perform best. Each model was trained
from different randomly initialised weight values.
The network was trained for 200,000 epochs. Two
hundred and fifteen sets of independent data were used for
testing the network. This test data was generated from
‘Hoganäs’ [8] data sheets supplied for a number of grades
of ferrous powder. A relatively good correspondence was
observed between the NN predictions, and the data sheet
values (errors were within 15% of the actual value). Train-
ing involved minimising the sum of the squares of the errors
for the output values, using simple back propagation with
variable learning rate. The weights and biases were updated
using the formula [12]:
wbk11 ˆ wbk 2 ak gk …2†
Here wbk11 is the weight and bias vector at the …k 1 1†th
iteration. ak is the learning rate, and gk is the current gradi-
ent of error vector, with respect to weight. i.e. gk is 2E=2wb:
E is Sum Squared Error …SSE†: E ˆ …Tp 2 Yp †2 =2 …3†
where Tp is the target output, and Yp is the network output for
the pth pattern.
The learning rate is decremented if the new E calculated
at the new weight and bias is higher, while it is increased if
the same is lower by specified values.
The system was subsequently extended to identify a set of
ferrous powder grades from given mechanical property
combinations using heuristic rules. It then recommends
appropriate process parameters for the selected grades
using the NN. Subsequently the network outputs, (i.e.
compaction pressure, sintering temperature, alloy additions
and sintering atmosphere) were employed as the inputs for a
second network, in order to predict dimensional variations
and a cost index. The dimensional variation and cost index
were relative figures, based on information from the CASIP
database. The system employs a trained NN for each of a
number of grades of plain iron and pre-alloyed ferrous
powder. The operation of the system is illustrated in the
flow chart of Fig. 1.
Fig. 2 is a plot of experimental data, (obtained from a
Hoganäs data sheets) versus corresponding NN predictions
for the density of sintered part. Predictions made using the
second network for dimensional variations are plotted
against the experimental values in Fig. 3. A linear correla-
tion can be observed; in fact the predicted results lie within
^15% of experimental data, for all the predicted process
settings and chemical compositions (i.e. alloy additions).
Table 1 shows the required mechanical properties, (i.e.
1† the system inputs) with the corresponding test data and
predicted process settings (i.e. system outputs). Regression
analysis of the density data confirmed a direct proportion-
ality between the experimental and simulated values, with a
correlation coefficient of 0.992.
3. Discussion
The creation of a new design for a component to be
manufactured by Powder Metallurgy technology requires
input from experts in a number of fields. The areas of
 R.P. Cherian et al. / Artificial Intelligence in Engineering 14 (2000) 39–44
Fig. 1. System operation for NN based material and process parameter
selection.
expertise include powder packing and compaction beha-
viour, tooling design, processing parameters and powder
characteristics on the quality of the manufactured part.
These experts usually liase with the design engineer as an
acceptable design configuration emerges. Even after
production starts, their knowledge is needed in order to
achieve stabilised production, minimised tool maintenance
costs, and on-going design optimisation. The challenge for
computer based systems, is to facilitate knowledge storage
and processing, in order to generate advice for the designer
which is of a similar nature to that of the experts. It is likely
that this will require application of a combination of Artifi-
cial Intelligence (AI) methods, forming a Hybrid Knowl-
edge Based System. A critical element that needs to be
incorporated in these systems is the dynamic learning ability
43
Fig. 2. Plot of experimental data versus corresponding NN predictions for
sintered density (units are g cm 23).
Fig. 3. Dimensional variation predicted by ANN and the actual values
(percentage dimensional change).
of the type suggested in this paper. The advice given by the
process experts relies almost entirely on their knowledge,
the quality of which improves over time. In a competitive
manufacturing environment, the designer needs to incorpo-
rate design parameters, which rely heavily on recently
learned process related knowledge. Machine learning can
facilitate this process, and it is suggested that one of the
most powerful methods for implementing machine learning
is the NN.
NN based techniques can be applied in generating
production advice relating to many aspects of PM, including
design, materials selection, and process control. However,
PM materials selection, which has been the main focus of
this paper, is particularly well suited to the application of
NN methods. This is because none of the models proposed
in literature accounts for all the process variables (sintering
temperature, compaction pressure etc.) limiting their applic-
ability in real life problems. NNs are well suited to the
modelling of these highly non-linear functions from noisy
44 R.P. Cherian et al. / Artificial Intelligence in Engineering 14 (2000) 39–44
data, and in comparison to conventional statistical models,
an increase in the accuracy of predicted process outcomes
has been demonstrated. Another advantage offered by this
approach is the capability for machine learning through
retraining of the network when new data is generated.
This retraining will facilitate knowledge maintenance, and
it will help to ensure the KBS will remain a useful tool for
generating various types of design and production advice.
4. Conclusions
The system described in the paper assists the powder
metal selection in PM and demonstrates the advantages of
using NN methods, in combination with heuristic techni-
ques, for the development of knowledge based advisory
systems for manufacturing. Such systems can assist with
the implementation of Concurrent Engineering practices,
through timely provision of basic and critical production
knowledge, at an early stage in the design of the component.
The consequent avoidance of expensive re-designs or shop
floor problems is, in the long term, expected to enable
manufacturers to realise significant lead-time and cost
reductions. These benefits could be further enhanced prior
to the commencement of the production run, through
verification of the predicted process settings.
The work reported here supports the overall objective of
the research being undertaken by the authors to enable
development of a Knowledge Based System, (KBS) for
PM. The intention is for this system to provide accurate
and timely advice, relating to the design and manufacture
of powder metallurgy parts.
Acknowledgements
The authors wish to thank Hoganäs AB, Sweden for the
use of experimental data from CASIP Database.
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