Abstract: A method of making a composite powder metal disk for a rotor assembly in a synchronous reluctance machine. The method includes filling discrete regions of a disk-shaped die with ferromagnetic and non-ferromagnetic powder metals, compacting to powders, and sintering the compacted powders. By this method, a disk is formed that includes alternating regions of magnetically conducting powder metal and magnetically non-conducting powder metal compacted and sintered to a high density. The method may also include forming a rotor assembly by stacking a plurality of the composite powder metal disks axially along a shaft with their magnetic configurations aligned.

Abstract: A composite powder metal disk for a rotor assembly in an induction machine. The disk includes a magnetically conducting powder metal segment and a plurality of axially extending slots around the exterior surface of the disk. In each slot is a conductor, for example cast aluminum or copper bars, enclosed within the slot by a magnetically non-conducting powder metal segment. A rotor assembly is also provided having a plurality of the composite powder metal disks mounted axially along a shaft with their magnetic configurations aligned. A method for making the powder metal disks is further provided including filling a die with the powder metals, compacting the powders, and sintering the compacted powders.

Abstract: A composite powder metal disk for a rotor assembly in a synchronous reluctance machine. The disk includes alternating regions of magnetically conducting powder metal and magnetically non-conducting powder metal compacted and sintered to a high density. A rotor assembly is also provided having a plurality of the composite powder metal disks mounted axially along a shaft with their magnetic configurations aligned. A method for making the composite powder metal disks is further provided including filling a die with the powder metals, compacting the powders, and sintering the compacted powders.

Abstract: A method for forming composite parts of two or more dissimilar materials by injection molding. Two or more different metallic- or ceramic-based powder materials are used to form two or more different feedstocks, which are each melted and injected under heat and pressure into mold cavities and allowed to solidify to form a composite green compact. In an example of the present invention, two or more powder materials are each mixed with a binder system and granulated to form feedstocks, the feedstocks are melted and concurrently or sequentially injected into a mold and allowed to solidify, and the solidified composite green compact is then subjected to binder removal and sintering processes.

Abstract: A method for forming composite motor parts of two or more dissimilar materials by injection molding. Two or more different powder materials are injected under heat and pressure into cavities of a cylindrical-shaped mold and allowed to solidify to form a composite green compact. The final part may be used in machines of the type including permanent magnet, synchronous reluctance, switch reluctance and induction machines.

Abstract: Disclosed is a method of shaping powdered metal parts comprising: (a) providing powdered metal from a source; (b) applying a heated fugitive coating to the powdered metal; (c) passing the powdered metal through a heated tube from a supply thereof to the die for the molding of the part; (d) monitoring the temperature of the heated tube during the passage of the powdered metal there through; (e) heating the die and monitoring the temperature thereof; (f) heating a punch die and monitoring the temperature thereof; (g) after filling the die with coated powdered metal, compacting the powdered metal by applying pressure from the punch die to the filled die thereby compacting the metal to a desired shape.