The Metal Powder Industries Federation's (MPIF) Awards Committee has announced the recipients of the 2023 MPIF Distinguished Service to Powder Metallurgy (PM) Award that recognizes individuals who have actively served the North American PM industry for at least 25 years and, in the minds of their peers, deserve special recognition.
Powder producers continue to respond to the needs of the industry by developing new and improved materials and additives for conventional press and sinter, MIM, and metal AM. Over the past two years, dry lubricants have been in limited supply and high demand, forcing companies to seek alternatives. The demand to improve “value‐added” machining has resulted in new high green strength materials that are suitable for green machining.
GKN Powder Metallurgy, a provider of powder metal solutions, recently announced its commitment to enter the permanent magnets for the electric vehicle (EV) market, in response to the supply challenges the industry is facing.
20/20 is considered to be perfect vision, but the year 2020 outlook is quite obscure. We can view the current state of the PM industry through short-term, fear-tinted glasses or gain a clearer picture of long-range opportunities. Just like U.S. manufacturing in general, the PM industry has been impacted negatively by the pandemic.
Due to production by pressing and sintering, PM gears are porous. Since pores reduce the loaded area and are also probable crack initiators, the porosity determines the strength of the PM component. PM gears can be densified to increase their local density and, therefore, the load-carrying capacity. PM gears are compacted locally since they are mainly loaded directly at the surface. A common process to densify PM gears locally is the cold rolling process. The contact conditions in the cold rolling process determine the density profile and, therefore, the material properties of the PM component. The influence of the contact conditions in cold rolling of PM gears on the resulting density profile is yet to be investigated.
The properties of both shot-peened and cold rolled PM gears are analyzed and
compared. To quantify the effect of both manufacturing processes, the tooth root
bending fatigue strength will be evaluated and compared to wrought gears.
Powder metal (PM) gears normally sell due to the lower cost and their relatively high mechanical performance. The reason behind the lower cost is that most of the machining is omitted due to the net-shape forming process. So how net-shape are powder metal gears? In this article some hard-to-find information about the tolerances through the manufacturing steps will be presented.
Electrification has already started to have a noticeable impact on the global automotive industry. As a result, the drivetrains of hybrid (HEV) and full electric vehicles (EV) are facing many challenges, like increased requirements for NVH in high speed e-Drives and the need for performance improvements to deal with recuperation requirements. Motivated by the positive validation results of surface densified manual transmission gears which are also applicable for dedicated hybrid transmissions (DHTs) like
e-DCTs, GKN engineers have been looking for a more challenging application
for PM gears within those areas.
When manufacturing powder metal (PM) gears lead crowning is not achievable in the compaction process. This has to be accomplished either by shaving, grinding or honing. Each of these processes has their merits and draw backs. When employing rolling using a roll burnishing machine lead crowning can be accomplished but due to errors in profile a hard finishing operation such as grinding is used by the industry. In this paper a helical PM gear that has sufficient tolerance class after rolling has been tested in a test rig for durability and the wear has been studied.