Abstract: A powder metal alloy composition is used in the production of a sintered powder metal insert for casting into an aluminum casting. The powder metal alloy composition includes an iron powder metal base, copper such that the copper is 3.5 weight percent or more of the powder metal alloy composition, and carbon in an amount of 0.1 to 1.0 weight percent of the powder metal alloy composition. Upon compacting and sintering the powder metal alloy composition to form the sintered powder metal insert, the sintered powder metal insert has a copper gradient that provides a higher concentration of copper on the surface of the sintered powder metal insert than in a center of the grains of the sintered powder metal insert. The higher concentration of copper at the surface of the insert enables a strong metallurgical bond to be formed with the aluminum casting during casting.

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 method of forming a composite component having a brass or bronze powder metal portion sinter fit into a supporting, ferrous portion.

Abstract: A powder metal alloy composition is used in the production of a sintered powder metal insert for casting into an aluminum casting. The powder metal alloy composition includes an iron powder metal base, copper such that the copper is 3.5 weight percent or more of the powder metal alloy composition, and carbon in an amount of 0.1 to 1.0 weight percent of the powder metal alloy composition. Upon compacting and sintering the powder metal alloy composition to form the sintered powder metal insert, the sintered powder metal insert has a copper gradient that provides a higher concentration of copper on the surface of the sintered powder metal insert than in a center of the grains of the sintered powder metal insert. The higher concentration of copper at the surface of the insert enables a strong metallurgical bond to be formed with the aluminum casting during casting.

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 method includes the sequential steps of compacting a powder metal in a tool and die set using a compaction press to form a powder metal compact, ejecting the powder metal compact from the tool and die set, positioning the powder metal compact relative to another part, and cooling the powder metal compact. When the powder metal is compacted, a temperature of the powder metal used to form the powder metal compact increases relative to ambient temperature due to deformation of the powder metal during compacting. After ejection and while the powder metal compact is still above ambient temperature, the compact is positioned relative to the other part. Then, upon the cooling of the powder metal compact, the powder metal compact dimensionally shrinks to form an interference fit between the powder metal compact and the other part thereby forming the composite component, which may be subsequently sintered.

Abstract: A brazed part includes two or more components that are brazed together and has related method of making. Using a method of locating parts relative to one another, an inter-component gap between the components may be formed. Subsequently, during brazing, flow control features formed along the inter-component gap may then be used to assist in the retention of the braze material between the components during brazing.

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: A method includes the sequential steps of compacting a powder metal in a tool and die set using a compaction press to form a powder metal compact, ejecting the powder metal compact from the tool and die set, positioning the powder metal compact relative to another part, and cooling the powder metal compact. When the powder metal is compacted, a temperature of the powder metal used to form the powder metal compact increases relative to ambient temperature due to deformation of the powder metal during compacting. After ejection and while the powder metal compact is still above ambient temperature, the compact is positioned relative to the other part. Then, upon the cooling of the powder metal compact, the powder metal compact dimensionally shrinks to form an interference fit between the powder metal compact and the other part thereby forming the composite component, which may be subsequently sintered.

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 method of forming a composite component having a brass or bronze powder metal portion sinter fit into a supporting, ferrous portion.

Abstract: A process for manufacturing connecting rods is provided which comprises the steps of compacting, sintering, and powder forging a powder metal comprising a carbon source and a prealloyed powder consisting essentially of iron and copper. The connecting rods made from this process have sufficient hardness and strength to be used in an engine and do not require any additional quenching or tempering.

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: A brazed part includes two or more components that are brazed together and has related method of making. Using a method of locating parts relative to one another, an inter-component gap between the components may be formed. Subsequently, during brazing, flow control features formed along the inter-component gap may then be used to assist in the retention of the braze material between the components during brazing.

Abstract: A method of joining multiple powder metal components to form a powder metal component assembly using an adhesive is disclosed. By machining at least one of the powder metal components prior to the adhesive joining, otherwise difficult to machine features can be more easily machined for less cost and at higher production rates. Unlike high temperature joining techniques, the adhesive joins the powder metal components at room temperature. This room temperature adhesive joining eliminates the thermal distortions in pre-joined machined features common to high temperature joining techniques such as brazing or welding that bring these features out of specification during joining.

Abstract: A brazed part, and methods of forming a brazed joint therein, are disclosed. The brazed part includes two or more components that are brazed together. Using the method of locating the parts herein disclosed, an inter-component gap between the components may be formed. Flow control features formed along the inter-component gap may then be used to assist in the retention of the braze material between the components during brazing.