Abstract: The invention provides an accurate powder metal component having a body with opposed surfaces at least one of which has at least one projection of smaller cross-sectional area than the main portion of the body of the component. The distance from the free end of the projection to the opposite end of the component defines one dimension of the component that must be relatively accurate, in one embodiment to slide against and form a seal that inhibits liquid flow against another component of an assembly. In the manufacturing method, the powdered metal component is made by compaction to form the body including a projection at the end, is sintered and thereafter is reduced in the dimension between the end of the projection and the opposite end of the component by coining the free end of the projection so as to reduce the dimension to within a tolerance of the nominal specified dimension.

Abstract: A powder metal component (34) has an outer diameter that is inserted in a bore of another component (18) during assembly with an interference fit between the two components. Ribs (30) are formed on the outer diameter of the component (34) during compaction and sintering of the component. The ribs (30) have a surface that has been compressed to a greater density than a surface (31) of the outer diameter between the ribs to produce a major diameter and effective roundness defined by high points of the ribs.

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 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 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 powder metal component (34) has an outer diameter that is inserted in a bore of another component (18) during assembly with an interference fit between the two components. Ribs (30) are formed on the outer diameter of the component (34) during compaction and sintering of the component. The ribs (30) have a surface that has been compressed to a greater density than a surface (31) of the outer diameter between the ribs to produce a major diameter and effective roundness defined by high points of the ribs.

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.

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: The invention provides an accurate powder metal component having a body with opposed surfaces at least one of which has at least one projection of smaller cross-sectional area than the main portion of the body of the component. The distance from the free end of the projection to the opposite end of the component defines one dimension of the component that must be relatively accurate, in one embodiment to slide against and form a seal that inhibits liquid flow against another component of an assembly. In the manufacturing method, the powdered metal component is made by compaction to form the body including a projection at the end, is sintered and thereafter is reduced in the dimension between the end of the projection and the opposite end of the component by coining the free end of the projection so as to reduce the dimension to within a tolerance of the nominal specified dimension.

Abstract: The present invention provides a method for making metal parts from metal powder compositions comprising an iron base metal powder and an amide lubricant. The method comprises the steps of compacting said composition, pre-sintering the compacted composition, compacting the compacted and pre-sintered composition, and sintering the recompacted composition. The metal parts have improved physical and mechanical properties.