Single Press to Full Density for Automotive Powertrain Components: Gears and Sprockets

The PM Industry Roadmap prepared in 2001 identified six top-priority research needs for the industry, including one entitled “develop material and processing technologies to achieve 100% density while maintaining dimensional tolerances and cost-effectiveness”. The Center for Powder Metallurgy Technology (CPMT) recognized this need as its top priority and put together a task force to establish a multi-year program plan to meet this need. Additional targeted funds were solicited to help offset the added costs of this major project, including the hiring of a special project leader. A two phased program was developed with the first target a 7.5+ g/cc density for structural steels through single press-single sinter processing and then a “stretch” target for Phase 2 of 7.7+ g/cc density. The four tasks identified for the Phase 1 program are described including the advanced technologies being investigated, the materials, equipment and processes used and the outcomes to be measured. A progress report update will identify the accomplishments to date, the problems encountered and the options yet to be investigated.