Abstract: A method of manufacturing a sized powder metal component having improved fatigue strength. The method includes the sequential steps of solutionizing a sintered powder metal component and quenching the sintered powder metal component, sizing the sintered powder metal component to form a sized powder metal component, re-solutionizing the sized powder metal component, and ageing the sized powder metal component. The sized powder metal component made by this method, in which the component is re-solutionized between sizing before ageing, can exhibit exceptional improvements in fatigue strength compared to components prepared similarly but that are not re-solutionized.

Abstract: The mechanical properties and thermal resistance of a sintered component made from an Al—Cu—Mg—Sn alloy powder metal mixture can be improved by doping the Al—Cu—Mg—Sn alloy powder metal mixture with a silicon addition. Silicon is added as a constituent to the Al—Cu—Mg—Sn alloy powder metal mixture. The Al—Cu—Mg—Sn alloy powder metal mixture is compacted to form a preform and the preform is sintered to form the sintered component.

Abstract: A transition element-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminum-transition element melt in which a transition element content of the aluminum-transition element melt is less than 6 percent by weight. The aluminum-transition element melt then powderized to form a transition element-doped aluminum powder metal. The powderization may occur by, for example, air atomization.

Abstract: An improved aluminum alloy powder metal includes silicon additions. When this improved powder metal with silicon additions is sintered to form a sintered component, the resultant component exhibits many improved mechanical strength properties and improved thermal resistance.

Abstract: A method of manufacturing a sized powder metal component having improved fatigue strength. The method includes the sequential steps of solutionizing a sintered powder metal component and quenching the sintered powder metal component, sizing the sintered powder metal component to form a sized powder metal component, re-solutionizing the sized powder metal component, and ageing the sized powder metal component. The sized powder metal component made by this method, in which the component is re-solutionized between sizing before ageing, can exhibit exceptional improvements in fatigue strength compared to components prepared similarly but that are not re-solutionized.

Abstract: A transition element-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminum-transition element melt in which a transition element content of the aluminum-transition element melt is less than 6 percent by weight. The aluminum-transition element melt is then powderized to form a transition element-doped aluminum powder metal. The powderization may occur by, for example, air atomization.

Abstract: The mechanical properties and thermal resistance of a sintered component made from an Al—Cu—Mg—Sn alloy powder metal mixture can be improved by doping the Al—Cu—Mg—Sn alloy powder metal mixture with a silicon addition. Silicon is added as a constituent to the Al—Cu—Mg—Sn alloy powder metal mixture. The Al—Cu—Mg—Sn alloy powder metal mixture is compacted to form a preform and the preform is sintered to form the sintered component.

Abstract: An aluminum alloy powder metal is disclosed. A sintered part made from the aluminum alloy powder has a thermal conductivity comparable to or exceeding parts made from wrought aluminum materials.

Abstract: An improved aluminum alloy powder metal includes silicon additions. When this improved powder metal with silicon additions is sintered to form a sintered component, the resultant component exhibits many improved mechanical strength properties and improved thermal resistance.

Abstract: A zirconium-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminum—zirconium melt in which a zirconium content of the aluminum—zirconium melt is less than 2.0 percent by weight. The aluminum—zirconium melt then powderized to form a zirconium-doped aluminum powder metal. The powderization may occur by, for example, air atomization.

Abstract: A powder metal mixture is disclosed that provides improved mechanical properties for parts made from powder metal, such as cam caps. The powder metal mixture, upon sintering, forms an S phase intermetallic in the Al—Cu—Mg alloy system. The S phase is present in a concentration that results in an enhanced response to cold work strengthening of the powder metal part. Further, by minor adjustments to certain alloy elements, such as tin, the tensile properties of the resultant part may be adjusted.

Abstract: An aluminum alloy powder metal is disclosed. A sintered part made from the aluminum alloy powder has a thermal conductivity comparable to or exceeding parts made from wrought aluminum materials.

Abstract: A transition element-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminum-transition element melt in which a transition element content of the aluminum-transition element melt is less than 6 percent by weight. The aluminum-transition element melt then powderized to form a transition element-doped aluminum powder metal. The powderization may occur by, for example, air atomization.

Abstract: A zirconium-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminum-zirconium melt in which a zirconium content of the aluminum-zirconium melt is less than 2.0 percent by weight. The aluminum-zirconium melt then powderized to form a zirconium-doped aluminum powder metal. The powderization may occur by, for example, air atomization.

Abstract: A powder metal mixture is disclosed that provides improved mechanical properties for parts made from powder metal, such as cam caps. The powder metal mixture, upon sintering, forms an S phase intermetallic in the Al—Cu—Mg alloy system. The S phase is present in a concentration that results in an enhanced response to cold work strengthening of the powder metal part. Further, by minor adjustments to certain alloy elements, such as tin, the tensile properties of the resultant part may be adjusted.