High density powdered metal parts

Powdered metal parts when forming and sinter processes can be done, it has the lower cost while production rate is highest compared to others such as investment casting, Metal Injection Molding MIM,machining and forging.

The forming of 3D has some limits for the reasons of tool component feasibility and small sizes. Smaller parts are difficult to have multi-punch structure as punch is too small and thin, it can’t sustain the pushing force and bend or break.

Other consideration is the shortfall of powder metal strength requirement due to lower density.

By new process of better powder formula, and higher temperature sintering, now density of 7.6 g/cm3 has been achieved by compact and sinter process alone.

Strength of sintered parts is not linear but exponentially stronger. Traditional way to bring higher

density by better tool material and sacrificing tool life. But this doesn’t justify the total cost as tool component cost is very high. How to get higher density is always the pain of powder metallurgy manufacturers.

We have solved problems that make our customers happy:

Racks that are hard to form.

The part is not large enough and 3D Z axis requires 3rd punch to form.

When 3rd punch is to be arranged, the longer punch in slim dimension will cause the long punch to bend. It will make the parts when ejecting from the die not function immediately so the bending lower punch will remain pushing the parts when other punches are free. This will cause crack, the most difficult situation.

But carefully design the 3rd lower punch with minimum requirements, and fine adjusting the compaction operation, we finally solved it with satisfied results.

This part is used on heavy vehicle brake pad clearance adjustment. It must be defect free. Crack free. Subject to over specific pulling force after sintering and heat-treatment.

Needs fine serrations for providing required torque and gear profile correction. Importantly, compression test with minimum forces. Requires high density. Only specific powders are qualified to meet the need.