Keystone Powdered Metal Company

Keystone Investment Corporation

Other

Gary L Anderson

Bradley Reiter

Peter G Imbrogno

Kevin Brunner

Matthew G Herbstritt

William J Olson

John C Kosco

Peter Stauffer

Jerome E Muroski

It has been found that duplex monolithic parts can be manufactured in high volume at low cost by using powder metal technology to mold and sinter an inner component of the part into an outer component of the part. This technique reduces the cost of manufacturing intricate metal products by taking advantage of the attributes of powder metal technology in making the inner component of the part. The outer component of the part can be wrought machined, stamped or forged, or made by double press double sinter or forging a powder metal component of the part. In any case, this technique can beneficially be used in making a wide variety of toroid parts, such as gears, clutches, sprags, bearing races, one-way diodes, and the like.

Process for manufacturing toroid parts

The present invention discloses a clutch assembly which is comprised of (1) a cam plate which includes cams which are spaced about a central axis; (2) a rocker plate which includes at least one pocket, wherein the pocket includes a first rocker plate engagement surface and a second rocker plate engagement surface; and (3) at least one rocker which is pivotally situated within the pocket of the rocker plate, (4) a first solenoid, and (5) a second solenoid, wherein the solenoids can be activated or deactivated to allow for the clutch to be in a neutral position (to allow for free rotation in both clockwise and counterclockwise directions), to prevent rotation in a clockwise direction while allowing for free rotation in a counterclockwise direction, or to prevent rotation in a counterclockwise direction while allowing for free rotation in a clockwise direction.

Two-way clutch assembly

By utilizing the technique of this invention, parts such as gears, bearing races, and one-way clutches, which could previously only be made via labor intensive machining procedures can be made utilizing power metal technology. The subject invention provides a method of manufacturing a high strength part which comprised (1) providing an external component having an external profile and an internal profile, wherein the external component is comprised of a forged powder metal or a wrought metal; (2) compacting a powder metal composition within the internal profile of the external component to produce a green internal component having a desired internal profile; and (3) sintering the green internal component within the confines of the external component to produce high strength part, and wherein the internal component is comprised of a powder metal which expands to a greater degree than does the forged power metal or the wrought metal during sintering.

High strength part having powder metal internal ring

Rocker

Rocker with circumferential tail

It has been found that metal parts having rough surfaces can be manufactured by (1) compacting a metal powder under high pressure in a mold to make a green part, wherein at least one face of the mold is roughened by electrical discharge machining to have an Rof 10 to 200 micro-inches, as measured with a profilometer having a stylus tip, (2) heating the green metal part to a temperature of at least 1500&#xb0; F. to sinter the green metal part to produce the metal part having at least one rough surface, wherein the rough surface has an Rwhich is within the range of 10 to 200 micro-inches, as measured with a profilometer having a chisel tip, and (3) optionally, buffing, classifying, deburring and/or washing the metal part. This method can be beneficially used in manufacturing clutch plates, pressure plates, and cam shaft sprockets.

Surface roughening of powder metal parts

The subject invention discloses a process for strengthening and obtaining the desired dimensions for a metal part comprising: (1) heating at least a portion of a preformed metal part to a temperature above about 1300&#xb0; F. to transform the metal in at least said portion of the part to an austenitic state to produce an austenitized preformed metal part, (2) quenching the austenitized preformed metal part to a temperature of 300&#xb0; F. to 650&#xb0; F. to put the metal in the preformed part in a metastable austenitic state, (3) coining, drawing or extruding the preformed metal part while said metal of said preformed metal part is maintained in the metastable austenitic state at a temperature of 300&#xb0; F. to 650&#xb0; F., and (4) quenching the coined, drawn, or extruded metal part at a temperature which allows for the rapid transformation from austenite to martensite.

Method of strengthening metal parts through ausizing

A chinrest pad system designed to hold a standard chinrest used with a string instrument that minimizes dampening of vibration and prevents damage caused by the metal components touching the edges of the instrument. The system includes pads located under the support surface of the chinrest member and on top of the lower lip plate used on the lower clamping member. The pads are specifically designed to partially engage the instrument's upper and lower edges and match the curvature of instrument surface immediately adjacent to the edge. Each pad also includes a rear extending lip that bends slightly around the upper or lower edge and extends rearward to prevent the metal rods used with the turnbuckles from contacting the rear surface. During assembly, the pads are positioned over the upper and lower edges so that the compression forces exerted by the support surface and the lower lip plate are centrally located over the sidewall transverse axis, thereby minimizing dampening of vibration.

String instrument chinrest pad system

The present invention relates to a low cost technique for manufacturing dual helical gears, such as herringbone gears, from powder metals. The dual helical gears made by this technique are of high density (greater than 92% of theoretical density) and offer superior strength. The present invention more specifically discloses a forged metal herringbone gear which is comprised of a body and a plurality of teeth wherein the metal has a density of greater than 92% of theoretical and wherein the grain in the teeth is one range higher on the ASTM E 112 grain size chart than the grain in the body of the gear.

High density dual helical gear

The present invention relates to a low cost technique for manufacturing dual helical gears, such as herringbone gears, from powder metals. The dual helical gears made by this technique are of high density (greater than 92% of theoretical density) and offer superior strength. The present invention more specifically discloses a forged metal herringbone gear which is comprised of a body and a plurality of teeth wherein the metal has a density of greater than 92% of theoretical and wherein the grain in the teeth is one range higher on the ASTM E 112 grain size chart than the grain in the body of the gear. The present invention also discloses a method for manufacturing a high density forged dual helical gear.

Growing community of inventors

St. Marys, PA, United States of America

Gary L Anderson