Study of Galena Ore Powder Sintering and Its Microstructure

Galena is a natural mineral enriched with lead sulfide (PbS). It typically forms in hydrothermal veins associated with igneous rocks and can also occur as a gangue mineral in other ore deposits. PbS is of special importance for scientific research applications due to the possibility of tuning its semiconductor energy gap using nanotechnology in conjunction with powder metallurgy as an easy, controllable production route. In this paper, almost pure PbS was successfully produced starting from a high ratio of PbS phase galena ore. As-received galena lumps were roughly pulverized and milled to produce four particle size ranges of 38, 63, 125, and 250 µm prior to compaction and sintering in a vacuum (pre-flushed with argon gas). SEM coupled with the EDAX analysis unit was employed to investigate the microstructure and chemical composition of the as-received galena and the subsequent products after sintering. The chemical analysis confirmed the high ratio of PbS compound in the as-received galena and sintered products with approximately 85% Pb and 13% S mass ratio. The sintering process of the galena powder was carried out at different values of temperature, time, and compaction pressure. Additionally, the effect of length to diameter ratio of compacted and sintered samples was investigated. XRD analysis confirmed the existence of the PbS phase in the as-received and sintered samples at 700 °C with approximately 98 wt.%, as well as a new phase that is formed at 800 °C with a lower percentage. The micro-hardness of the as-received and sintered samples was measured and compared with the as-received galena ore. The results showed a significant reduction in the hardness of sintered galena powder compared with the bulk as-received galena by 52%. Furthermore, a relative sintered density of 99.3% for the as-received galena density signifies a novel result using powder metallurgy techniques.