Mitsubishi Materials PMG Corporation, Tokyo, took home a grand prize in the automotive chassis category for a gear set with high strength used in a new tilting and telescoping steering column. The tooth lock and two cams making up the gear set were produced from diffusion-alloyed PM steels. They have a density of more than 7.05 g/cm³, a tensile strength more than 159,000 psi and a 57 HRA hardness.
In the hardware/appliances category, Capstan Atlantic of Wrentham, MA won the grand prize for a PM steel gear set (pictured) used in a high-volume business machine printer. Roll densified to a surface density of 7.8 g/cm³, the gear has an AGMA quality 10 precision level, and the pinion has an AGMA 8 level. The gear and pinion have a core density of 7.3 g/cm³, and the gear-tooth-surface fatigue resistance matches that of a wrought steel 8620 carburized gear. The single-pressed gear replaced two machined gears and saved more than 40 percent in cost.
A grand prize was awarded to Parmatech Corporation, Petaluma, CA, in the medical, dental category for a 17-4 PH stainless steel articulation gear that was used in a surgical stapling unit. This part was formed by injection molding to a density greater than 7.65 g/cm³ with tensile strength of 130,000 psi, a yield strength of 106,000 psi and a 25 HRC hardness. Finishing processes were unnecessary in the gear’s production, which saved 70 percent in cost.
A low-alloy steel intake and exhaust sprockets, used in a variable valve timing system for a high-performance, double-overhead cam V-6 engine, received an award of distinction in the automotive engine category. Produced by Cloyes Gear & Products Inc., Paris, AR, the sprockets used warm compaction to form to a density of 7.25 g/cm³. The high-strength timing sprocket achieves cam phasing functions. The sprockets have a typical tensile strength of 170,000 psi, a 52,000 psi fatigue limit and compressive yield strength of 183,000 psi.