Let’s Talk Economics: Powder Metals – Solid Relations

Powder metallurgy is a precision metal forming technology that is a part of the economic breakthrough for today’s manufacturers. The concept implies the manufacturing of parts–net to near-net shape–and is preferred to by manufactured gear makers.

Powder Metals and Manufacturers

Powder metal (P/M) and gear makers have established a solid relationship. This particular type of technology continues to advance as an enhancement to density and strength. According to sources, major automakers are increasing their usage of this product, which is used in transmissions and engines (as gears). And with the use of new high speed steel alloy cutting tools, gears are being produced.

Frankly, gear performance characteristics are based on the required surface hardness; core hardiness; hardness profile; grade of steel/micro-structure of steel; and residual stress distribution. Today, metal industry enthusiasts claim that most of today’s P/M gear capabilities are adequate, in relation to shape complexities and tolerance; however, they tend to ‘fall short’ on hardiness.

Heavy Density

Heavy density is what gear makers are after. ‘Near-fully’ dense P/M products: the part as less than 1% residual porosity or emptiness within its structure. The four most effective methods of compacting are powder forging, isostatic pressing, metal injection, and spray forming. And with powder forging, a work-piece is pressed into shape (preform). Then, the same piece is sintered, placed into a forge, and re-struck until fully compacted into the designed shape. More steps may be added to suit.

Chiefly, this particular method has become popular for producing a lot of powder metal steel products that possess ‘wrought’ steel properties-gears. Ideally, a ‘solid’ metal part structure provides a smooth surface that is free of voids, cracks, notches, and porous activity; while improving heat treating conditions-exhibiting enhancing gear characteristics: bending fatigue strength, impact strength, durability and endurance levels-powder metal production.

Unique Metals

A powder alloy is available to gear manufactures. The metal types vary from beryllium, titanium alloys to aerospace super-alloys and high speed steel bridge alloys. Surprisingly, powder alloy is topping the charts–of economical might–in producing gear forms with key-ways, drive-lugs, splines, and other mandated products that relate to manufacturing industries for aviation, automotive, and industrial professions.

By Popular Demand

By popular demand, according to metal technology users, the automotive industry has the largest demand for powder metal gears. Commonly, today’s transmissions require strength and fatigue properties; however, industry manufacturers-Philip Krupp, President of P/M Krupp Technologies, Inc.–tends to send remarks, “Automotive is probably the biggest driving force behind the quest for higher density… [while] transmission gears require strength and fatigue properties that are currently unavailable in conventional powder metal processing”.

In relation, according to Krupp, powder metal pre-form [gears] are preceded by eliminating manufacturing steps, which is economical to manufacturing firms in today’s economy. Plus, compared to cut gears, powder metal gears are to the economic advantage.

Ultimately, the methods of using powder metals to create priceless parts continues to stimulate engineers and investors, due to its up and coming technological promises; not to mention to difference in cost compared to cut gears for instance. In summary, powder metallurgy remains on point to sale, according to industry leaders.