Gears made by Capstan Atlantic that can be used in a commercial printer won the Hardware/Appliance Award. This gear set consists of two large and small gears. After surface densification, the surface density of the large gear is 7.8g/cm3. The density of the two gear cores is 7.3g/cm3. The manufacturing precision of the large gear is AGMA Q10, the manufacturing precision of the small gear is AGMA Q8, the fatigue strength of the large gear tooth is the same as that after the carbonization of the 8620 forged steel, and the gear set made by powder metallurgy replaces the original two machines. Processing gears can save more than 40%.
Kinetics Climax Co., Ltd. received a hardware/applianty class award for a set of lock assembly parts manufactured using a metal injection molding process. These metal injection molding process lock assembly parts are made of 17-4PH stainless steel. These lock assembly parts are composed of lock bars, pins and racks. The density of these powder metallurgy parts is 7.7g/cm3, typical tensile strength. The same is 128 000 psi, and the typical yield strength is 100 000 psi. These powder metallurgy parts work in a device called the Kwikset SmartKey drum, which can be easily used by the user. The use of metal injection molding processes to manufacture these parts can result in significant cost savings, and Black&Decker has used these new products.
A set of high-strength gear sets manufactured by Japan's Mitsubishi Materials PMG Co., Ltd., which can be applied to a new type of automobile driving system, won the award for the automobile chassis category. This gear set consists of a tooth lock and two cams made of powder metallurgy steel that has been diffusion alloyed. These powder metallurgy parts have a density greater than 7.05 g/cm3 and a tensile strength greater than 159 000 psi. These powder metallurgical parts are produced using a near-final method that replaces the forging and machining processes typically used to produce these parts. Fuji Electric (Fuji Kiko) Co., Ltd. has used these new products.
A series of stainless steel coil bobbins manufactured by ASCO Sintering Co., Ltd. won the Automotive Chassis Class Honor Award. These stainless steel coil formers can be used in new brake systems for racing and high-performance vehicles that greatly extend the fatigue life of the brake stator and also cushion the pressure, damping and thermal insulation generated by thermal expansion. These powder metallurgy parts have a density of 7.0 g/cm3, a tensile strength of 70 000 psi, a yield strength of 45,000, an elongation of 13%, a Rockwell hardness of 65 HRB, and an impact toughness of 48 ft·lb. The company has already used these new products.
A slotted disc and a set of discs developed by Burgess-Norton Manufacturing Company for use in a six-speed automatic transmission won the Grand Prix of the Automotive Transmission category. The notched disc and the sleeve are made of powder metallurgy sintered hardened steel with a notch weight of O.84 kg (1.85 lb) and a sheave weight of 1.15 kg (2.54 lb). The density of the two powder metallurgical parts is At 6.7 g/cm3, the slotted disc has a tensile strength of 75 000 psi and the sleeve has a tensile strength of 90 000 psi. Compared to parts made from forged steel, the powder metallurgy process saves about 70%. And can improve manufacturing accuracy. Ordinary industrial companies have used these new products, and the annual production of these two parts is estimated to exceed 2.5 million pieces, using about 3.63 million kg (8 million lb) of iron powder per year.
Parmatech Ltd. received a medical/dental award for connecting gears made of 17-4PH stainless steel. This connecting gear can be used in a surgical instrument that has a maximum tensile strength of 130 000 psi, a yield strength of 106 000 psi, a density of 7.65 g/cm3, and a Rockwell hardness of HRC 25. . Although the shape of the connecting gear is complicated and requires high manufacturing precision, the connecting gear made by the metal injection forming method does not require subsequent machining processing, and is used in comparison with the previously used machined bar method. The metal injection molding process can save about 70% of the cost.
The stator developed by PMG Ltd., which can be applied to a variable valve timing system (VVT) in a 1.4 L engine, won the automotive engine category. The stator is made of a kind of iron-copper powder metallurgy material with a density of 7.0g/cm3. The tight tolerance control of the stator during the manufacturing process can reduce the oil leakage of the pressure chamber during use. The fuel consumption and exhaust emissions are saved, and the performance of the engine is especially improved at low speeds. The Schaeffler Group has already used this new product.
The powder metallurgy low alloy steel inlet sprocket and export sprocket developed by Cloyes Gear and Other Products Co., Ltd. won the Automotive Engine Class Honor Award. These sprockets can be used in a variable valve timing system (VVT) for a high performance 6-cylinder engine. These sprockets are formed by a warm-press process, and the teeth of the sprocket are heat treated and tempered. The sprocket teeth have a Rockwell hardness of 70 HRA. These powder metallurgy parts have a density of 7.25 g/cm3. These sprocket wheels have a typical tensile strength of 170 000 psi and a typical fatigue strength of 52 000 psi. Typical The compressive yield strength is 183,000 psi.
FloMet Ltd. received the Electronics Honor Award for its hearing aid receiver housing manufactured by the metal injection molding process. The hearing aid receiver housing is made of a nickel-iron-molybdenum alloy. The magnetic modulation function of this material can separate the received signals from the pickup. The original process for producing such parts is complicated with the metal injection molding process. The metal injection molding process saves about 50% of the cost compared to the original production process, and also improves the mechanical properties of the product. Starkey Labs Ltd. has used this new product.
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