Powdered Metal Process
The powdered metal process involves compacting, and sintering powdered metals in order to form both simple and highly complex component parts such as sheaves, pulleys and high strength gears. Before the powdered metal process begins, the engineers at Phoenix Sintered Metals will help you select the most suitable material. Once selected from a variety of pressed metals, Phoenix will compact the metal into the appropriate shape using presses that exert tons of pressure.
These “green” pieces have the accurate shape but are still very brittle during this part of the process. Phoenix permanently hardens the powders by sintering the metal to a temperature just below its melting point. This process, known as sintering, ensures that the part will retain its shape. Phoenix undertakes the sintering process in furnaces that reach extremely high temperatures within a protective atmosphere that allows for the metallurgical bonding of the metal particles without altering the shape of the part.
Unlike other metal parts manufacturing methods, powdered metal parts require no secondary operations once they have completed the sintering process. However, Phoenix can perform any number of optional secondary processes in order to meet your particular needs including heat treating, tempering, steam treating, machining, drilling, tapping, grinding, honing, boring, lapping, plating, coating, painting, inspection including visual, NDT, and resonance, oil and resin impregnation, as well as assemble operations. These operations can increase the strength, resistance, or lubrication of the powdered metal part.
The Powdered Metal Process Gallery
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| The process starts with the purchase of raw materials from one of our suppliers. | Powders are compressed into a mold by forces ranging from 6 to 825 tons | Parts are considered 'green' until they are sintered |
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| An HC900 Honeywell Controller is used to control atmosphere as well as temperature flows by storing recipes for automatic set-up and eliminates the need for operator adjustments. | Conventional oil quench heat treat can be replaced by sinter hardening with specialized sintering equipment. | The powdered metal components can be sintered in furnaces that reach up to 2400° |
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| In order to increase density or tighten tolerances, manual or automatic sizing can be added. | Oil impregnation can be used for increased lubrication. Parts can also be dipped in rust-preventative solution. | Parts may also be placed in a tumbler to remove any rough edges |
Phoenix has extensive experience in the powdered metal parts process and can manufacture over 2,000 different products. Some of the most popular include blade adapters, sheaves, pulleys, and gears. These parts often weigh less than five pounds. You can view the manufacturing services that Phoenix offers at the powdered metal capabilities page.
For more information about the powdered metal process please call 814-268-3455 or click here to contact us.
