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About Powdered Metal Parts
Powder metal parts are created through powder metallurgy
(P/M). During this manufacturing process, solid ferrous and nonferrous
metal parts are created from metal powder. P/M is suitable for numerous
metals, including iron, low alloy steels, stainless steel, nickel, copper,
brass and silver. Powder metal part manufacturers first reduce metals
to individual particles through methods including atomization, chemical
precipitation, comminution and hydrogen reduction. The resulting powders
are impregnated with lubricant. Then, they are compacted in a die cavity
at ambient temperature, after which they are in a near net state, or “green
state.” Finally, the green parts are sintered in a furnace at temperatures
below the melting point of the metal to bond the particles without changing
the shape of the part. The sintering process also increases part strength
and controls the porosity of the part. Although the finished parts look
solid, they actually consist of small interconnected capillaries, which
cause the parts to be approximately 25% porous. Secondary operations
are not usually required, but parts may still need to be sized, deburred,
heat or steam treated, machined, plated or oil/plastic resin impregnated.
Sintered metal products have many benefits over parts produced through
other methods. The process results in little waste, as approximately
97% of the materials are used during the procedures. Sintered products
are not shape sensitive either. Powder metal part manufacturers create
parts close to tolerances, often eliminating the need for secondary operations.
Therefore, P/M is often the technique of choice for the production of
intricate parts requiring bends, projections and depressions. A wide
variety of shapes and designs can be sintered out of an almost infinite
choice of alloys, composites and associated properties. Powder metal
parts have controlled porosity for self-lubrication and for gas or liquid
filtration.
Powder metal part manufacturers provide equipment components for almost
every industry. Powder, or sintered, metal parts are utilized in a variety
of industrial applications in the automotive, hardware, electronic, computer
and lawn and garden industries. Powder metal parts are found in automobile
components, structural parts, filtration
systems and magnetic
assemblies.
Gears are particularly well-suited to the sintering process, as the inherent
porosity of powder metal parts naturally dampens sound. Bushings and
bearing are also simple to produce through this process, though their
tight tolerances usually require a secondary sizing operation. P/M is
a popular choice for parts with magnetic properties, as the soft magnetic
material is usually difficult to form, limiting the choice of shapes.
However, powder metal can be easily formed in a wide variety of shapes,
and its magnetic properties are enhanced in the proper sintering atmosphere.
When designing powder metal parts to be sintered, several factors must
be taken into account. The shape of the part must allow for its ejection
from the die. Thin walls, narrow splines or sharp corners weaken the
overall strength of powder metal parts. Having too many levels in the
part results in a considerable variation of density, which can be problematic.
Shapes should be simplified as much as possible and allow reasonable
clearance between the top and bottom pressing. Dies and punches should
be made without sharp edges.
Featured
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Types of Powdered Metal Parts
- is a metal powder made from aluminum materials.
- is created through powder metallurgy and can be formed into solid components through the tool and die process.
- is formed into solid components through the application of pressure and heat.
- are often self-lubricating, providing low noise level, space
savings and low maintenance requirements. Lubrication is achieved through
the impregnation of oil into the bearings, which aids bearing performance
during rotary support of moving parts.
- commonly provide support to rotating axles and other shafts
in engines, drive systems and other equipment. Like bearings, powdered
metal bushings can be lubricated through impregnation to increase efficiency.
- are cost-effective and advantageous in industrial applications
involving difficult shape requirements. Gears provide speed and directional
changes to motion in transmissions, power tools, appliances and a variety
of other equipment.
- are particularly common in the automotive industry in
exhaust, fuel and brake systems, engine parts and transmission components.
Sintered parts are also found in computer and electronic equipment.
- is a solid metal made from adhered particles of powered bronze.
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contain uniform porosity, which increases functioning. In addition,
sintered filters are strong, easy to clean and heat resistant.
- is a solid product made by a cold forming process that presses metal powder into a coherent mass.
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