Powder metal (P/M) and gear makers continue to team up while creating geared parts. Along with this particular endeavor, new metallurgy-related demands are mentioned at the corporate conference tables. Ideally, powder metallurgy remains on the list of the industry’s economic value [tables]. Chiefly, a net to near-net shape is the desired piece for the future of gear-metal makers. The idea of this kind of concept promoted the density and strength of the part. As a result, an abundance of automakers is doubling the demand for this type of product that is used in today’s vehicle transmissions and engine gears. Additionally, this industrial demand constitutes utilizing high-speed steel alloy cutting machines to create gears efficiently.
Surprisingly, science has convinced researchers that the specific performance of certain gears relies on the surface hardness; core hardness; hardness profile; grade of steel/micro-structure of steel; the residual stress of distribution. In relation, today’s metal industry enthusiasts declare power metal gears as capable in shape complexities and tolerance; however, according to sources, the hardness tests are not good enough.
Heavy density gear making is the ticket and ‘near-fully’ powder metal product density represents less than 1% residual porosity (i.e. emptiness) within its structure. Moreover, there are four effective methods of compacting: powder forging; metal injection; isostatic pressing; and spray forming. Ideally, powder forging entails pressing a work-piece into shape (a preform). Next, the same object is sintered; placed into a forge; and re-stuck until it is compacted fully into the desired shape as designed. Later, additional step are applied (as needed).
Promoting [Powder Metal] Popularity
Frankly, this type of powder forging process promotes popularity, because of the demand for steel products that contain ‘wrought’ steel properties (e.g. gears). In relation, it is justified as a ‘solid’ metal part containment that provides a friction resistant surface that is free of voids, notches, crack, and porous activity. In addition, this method enhances heat treating conditions, but exhibiting improved gear characteristics (i.e. bending fatigue strength, impact strength, durability, and endurance levels)–powder metal production.
Availability in Today’s Market
The availability of powder alloy to gear manufactures is allocated in beryllium, titanium, highway speed steel bridge alloys, as well alloys to aerospace super alloys. Furthermore, powder alloy is known in gear forms with key-ways, drive-lugs, splines, and other parts that relate to aviation and automotive industries. Powder alloy is available as point-to-sell for industrial leaders.