Powder metal gears are found in aerospace, agricultural, automotive, building and construction, marine transportation, material handling, medical, military, petrochemical, pharmaceutical, power generation and robotics industries. The demand for application specific metal gears has led to the introduction of several types or styles such as anti-backlash, bevel, miter, chance, cluster, differential, helical, herringbone, hypoid, internal, planetary, spur and pinion gears. While these mechanisms can be produced in a number of machining processes, powder metal parts provide several advantages over traditional gear manufacturing methods. Read More…
Leading Manufacturers
Perry Tool & Research, Inc.
Hayward, CA | 510-782-9226Since 1962, Perry Tool and Research has manufactured complex powdered metal parts with premium surface finishes and long life cycles. Our powder metallurgy production processes ensure close tolerances and repeatability. Our specialization includes the production of gears up to 12 AGMA, self-lubricating bearings, soft magnetic components as well as custom mechanical parts. We value each customer and strive to provide exceptional customer service.
Webster-Hoff Corporation
Glendale Heights, IL | 630-858-8030At Webster-Hoff, we value quality in both manufacturing powder metal parts, and in customer service. Our team of engineers have the necessary skills to analyze the demands of our customers and utilize our state-of-the-art equipment to manufacture their desired powdered metal products. We work with a variety of materials including copper, brass, stainless steel, and iron, and we offer secondary services such as heat treating and CNC machining. Visit our website today to learn more!
Catalus Corporation
St. Marys, PA | 814-781-7004Catalus Corporation is a leading manufacturer of powder metal parts. Our products include parts used in the automotive, marine, heavy truck, lawn and garden, and recreational vehicle markets. We work with a variety of materials like iron, stainless steel, brass and bronze. Our research and development is done at our Galeton, PA facility and we offer strong engineering support and design assistance to our customers. We are registered to both the IATF-16949:2016 and ISO 9001:2015 standards.
Precision Sintered Parts
Tulsa, OK | 918-663-7511Since 1967, PSP has been a leader in small, intricate custom powdered metal parts for a wide range of industries, such as Sports & Recreation, Power Tools, Industrial Equipment, Oil & Gas. We make the economic benefits of powder metallurgy – or P/M – available to a wider range of customers. Let us show you the superior design, consistency, precision & finish over casting, forging or machining.
National Sintered Alloys, Inc.
Clinton, CT | 860-669-8653Our products serve industries such as transportation, hardware and tools, garden and law, as well as many others. We have been committed to producing the metal powder parts that you can count to keep your business moving for well over fifty years. Our research and development team keeps our customers on the leading edge of innovations at all times to better serve you. Visit our website today to learn more!
Powder Metal Gears - Perry Tool & Research, Inc.Most of the benefits arise specifically from the versatility allowed in press-and-sinter processing. The ability to produce multilevel gears, internal configurations and very close tolerance components eliminate or reduce the need for secondary operations, thereby cutting costs and saving time.
Powder Metal Mechanical Parts - Perry Tool & Research, Inc.The uniformity and reproducibility of these parts gives further economic value to powdered metal gears. Additionally, the porosity of sintered elements such as these allows for oil or resin impregnation which creates self-lubricating components, a feature that prolongs the working life of not only the gear, but the motor of which it is a part. The porosity, which can be closely controlled to suit specific requirements, also dampens sound and reduces the weight of a given part.
There are three basic steps to powder metallurgy, the process used to create powder metal gears. First, any of a number of techniques including atomization, flaking, pulverization, chemical reduction and electrolytic are used to reduce the initial raw metallic materials to a fine dust or powder. Specific amounts of this powder are then placed into the compaction die or mold where pressure is applied from both above and below in precise amounts relevant to the specific materials and intended use of the finished gear. This mold is pre-formed and results in the desired gear shape. After this form is ejected from the die, sintering is used to fuse the powder particles together.
The parts are placed on a moving belt which draws them through a controlled-atmosphere furnace, heating the compressed powder to just below the melting point of the raw materials. This temperature varies greatly, though a general rule is to use a temperature that is 2/3 that of the melting point for the primary metal. In this manner, the mechanical bonds of metal powders are converted into metallurgical bonds creating a solid mass from the powder. Gears can be composed of either a single metal or a composite material.
Common metals include aluminum, brass, bronze, cast iron, carbon or alloy steel, magnesium and titanium. Beyond materials, further considerations include, gear type, number of teeth, design units, tooth form, direction, gear center, pressure angle, gear features and mounting requirements.