Stackpole Limited

Formflo Limited

Peter Jones

Rohith Shivanath

Roger Lawcock

Danny Thien Thieu

Keith Buckley-Golder

Christopher John Cole

Karol Kucharski

D Sarafinchan

A process of forming a sintered article of powder metal comprising blending graphite, Si carbide and lubricant, with pre-alloyed iron base powder; pressing said blended mixture to a shaped article; sintering said article in a reduced atmosphere; forced cooling said sintered article.

Press and sinter process for high density components

The invention relates to methods of forming sintered compacts of low alloy steel composition to high density at ambient temperature. The invention provides for a method of forming sintered powder metal articles by forming the sintered powder metal in a die cavity having a clearance for movement of said sintered powder metal to a final shape with increased density after compaction wherein the formed sintered powder metal article has a compaction length which is approximately 3 to 30% less than the original length.

High density forming process with ferro alloy and prealloy

A method for making a high density powdered metal article is provided. In one embodiment, the composition consists of iron based powder, lubricant, graphite and ferro alloy additions. Satisfactory results may also be achieved by using fully prealloyed grades of metal powders, substantially pure powder blends, fully prealloyed powder blends, partially prealloyed powder blends and powder blends containing ferro alloys. The composition is compacted in rigid tools at ambient temperature, sintering at high temperature greater than 1100.degree. C. and then formed in rigid tools at 40 to 90 tons per square inch to a density greater than 94% of theoretical. The high density article is then annealed. The final article demonstrates remarkable mechanical properties which are atypical of powdered metal components and approach those of wrought steel.

High density forming process with powder blends

A method of densifying a sintered powder metal article by point contact.

Point contact densification

A manufacturing method is provided for the production of high density, high carbon, sintered powder metal steels. The composition consists of iron based powder, graphite, lubricant, and possibly at least one alloying element from the group of chromium, copper, manganese, molybdenum, nickel, niobium or vanadium. The composition is compacted in rigid tools, sintered and during cooling an isothermal or slow cooling treatment is introduced between 650.degree. C. and 750.degree. C. The isothermal or slow cooling treatment may alternatively be applied during a heat treatment cycle that is carried out after a conventional sintering cycle. The material processed as described may then be formed to high density. Forming to high density is not practical with high carbon materials that have been processed by conventional methods. The high density article is then heat treated in a manner to suit specific product requirements. The mechanical properties achieved by the claimed process offer significant benefits when compared to conventionally processed sintered powder metal articles.

High carbon, high density forming

A gear wheel is formed from a pressed and sintered powder metal blank in which the metal powder comprises an admixture of iron powder and at least one alloying addition and the gear wheel is surface hardened by applying densifying pressure only to the tooth root regions or only to the tooth flank regions in order to establish densification in the range of 90 to 100 per cent of full theoretical density to a depth of at least 380 and up to about 1,000 microns.

Gear wheels rolled from powder metal blanks

A method of making a sintered article of powder metal having a carbon composition in the range of about 0.8% to 2.0% by weight, then spheroidizing the sintered article and then warm forming the sintered article at a temperature between 250.degree. and 700.degree. C. for a time duration selected to form the article to a final shape.

Sintered hi-density process with forming

This invention relates to a method or process of forming a sintered article of powder metal, and particularly relates to a process of forming a sintered article of powder metal by blending combinations of finely ground ferro alloys (either singly or in combination with other ferro alloys) with elemental iron powder and other additives and then high temperature sintering of the article in a reducing atmosphere to produce sintered parts with oxygen contents less than 250 parts per million (ppm). More particularly the ferro alloys admixed to the base iron have a mean particle size of approximately 8 to 12 microns, having previously been ground to size in an inert atmosphere.

Powder metal alloy process

A method for making a high density powdered metal article is provided. The composition consists of iron based powder, lubricant, graphite and ferro alloy additions. The composition is compacted in rigid tools at ambient temperature, sintered at high temperature and then formed in rigid tools at 40 to 90 tons per square inch to a density greater than 94% of theoretical. The high density article is then annealed. The final article demonstrates remarkable mechanical properties which are atypical of powdered metal components and approach those of wrought steel.

Hi-density forming process

A powder metal gear wheel having a core density of at least 7.3 g/cc, and in one embodiment 7.4 to 7.6 g/cc and a hardened carburized surface. A method of manufacturing transmission gears comprises, sintering a powder metal blank to produce a core density of between 7.4 to 7.6 g/cc, rolling the surface of the gear blank to densify the surface, and then heating the rolled sintered part and carburizing in a vacuum furnace.

Gears

A gear wheel is formed from a pressed and sintered powder metal blank in which the metal powder comprises an admixture of iron powder and at least one alloying addition and the gear wheel is surface hardened by densifying at least the tooth root and flank regions to establish densification in the range of 90 to 100 percent of full theoretical density to a depth of at least 380 and up to about 1,000 microns.

Gear wheels rolled from powder metal blanks and method of manufacture

A process of forming a sintered article for powder metal comprising blending carbon and ferro alloys and lubricant with compressible elemental iron powder, pressing said blended mixture to form sintering said article, and then high temperature sintering said article in a reducing atmosphere to produce a sintered article having a high density from a single compression.

Hi-density sintered alloy

This invention relates to a process of forming a sintered article of powder metal comprising blending graphite and lubricant with a pre-alloyed iron based powder, pressing said blended mixture to shape in a single compaction stage sintering said article, and then high temperature sintering said article in a reducing atmosphere to produce a sintered article having a density greater than 7.4 g/cc.

Hi-density sintered alloy and spheroidization method for pre-alloyed

A method of producing bearing surfaces from powder metal blanks comprising: blending carbon and ferro alloys and lubricant with compressible elemental iron powder, pressing the blending mixture to form the powder metal blank, high temperature sintering the blank in a reducing atmosphere, compressing the powder metal blanks so as to produce a densified layer having a bearing surface, and then heat treating the densified layer.

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Toronto, Canada

Peter Jones