Abstract: A tool and die set and related method of use of the tool and die set in a press for the compaction of a powder metal into a preform involves an uneven amount of positional deflection of at least two lower or upper tool members. This asymmetrical elastic response under load may help to eliminate cracking of the part after the compressive load is removed.

Abstract: A tool and die set and related method of use of the tool and die set in a press for the compaction of a powder metal into a preform involves an uneven amount of positional deflection of at least two lower or upper tool members. This asymmetrical elastic response under load may help to eliminate cracking of the part after the compressive load is removed.

Abstract: An assembly comprising: a powder metal outer part (22) having a radially inward facing cylindrical surface (54) with a plurality of facets (52) formed thereon that, in an alternating fashion, extend in an axial direction from an axial side of the powder metal outer part toward an opposite axial side of the powder metal outer part to a position between the opposing axial sides of the powder metal outer part; a powder metal inner part (20) having a radially outward facing cylindrical surface with a plurality of facets formed thereon that, in an alternating fashion, extend in an axial direction from an axial side of the powder metal inner part toward an opposite axial side of the powder metal inner part to a position between the opposing axial sides of the powder metal inner part; and an intermediate component (26) disposed between the cylindrical surfaces of the powder metal outer part and the powder metal inner part that connects the powder metal outer part and the powder metal inner part together.

Abstract: A compression limiter is disclosed that comprises an upper surface and a lower surface. The compression limiter further comprises an inner surface that defines a passageway configured to accommodate a fastener and an outer surface configured to engage a structure in which the compression limiter is placed. A first retainer projects outwardly from the outer surface and includes a first retention surface that has at least a planar portion. The first retainer further includes an undercut surface disposed inwardly from the first retention surface so as to create a corner extending in a direction with at least a component perpendicular to the longitudinal direction. A method of forming the compression limiter is also disclosed.

Abstract: A compression limiter is disclosed that comprises an upper surface and a lower surface. The compression limiter further comprises an inner surface that defines a passageway configured to accommodate a fastener and an outer surface configured to engage a structure in which the compression limiter is placed. A first retainer projects outwardly from the outer surface and includes a first retention surface that has at least a planar portion. The first retainer further includes an undercut surface disposed inwardly from the first retention surface so as to create a corner extending in a direction with at least a component perpendicular to the longitudinal direction. A method of forming the compression limiter is also disclosed.

Abstract: A compression limiter is disclosed that comprises an upper surface and a lower surface. The compression limiter further comprises an inner surface that defines a passageway configured to accommodate a fastener and an outer surface configured to engage a structure in which the compression limiter is placed. A first retainer projects outwardly from the outer surface and includes a first retention surface that has at least a planar portion. The first retainer further includes an undercut surface disposed inwardly from the first retention surface so as to create a corner extending in a direction with at least a component perpendicular to the longitudinal direction. A method of forming the compression limiter is also disclosed.

Abstract: A powder metal insert for overmolding and method of making it has retention features on the outer surface extending from each end and angularly offset from one another.

Abstract: A cast metal connecting rod of the type used in a reciprocating piston engine has a beam section between two end sections. The beam section and the end sections are integral with one another and are at least partially made of a cast metal material. At least the beam section of the connecting rod includes an insert made of a sintered powder metal material. The insert is at least partially encapsulated by the cast metal material of the connecting rod. The insert reinforces the connecting rod and can help match characteristics of surrounding or mating parts of the engine that are made of materials more similar to the material of the insert than the cast metal of the connecting rod. The cast metal material, for example aluminum alloy, of the connecting rod can also provide localized regions of high machinability where needed.

Abstract: A compression limiter is disclosed that comprises an upper surface and a lower surface The compression limiter further comprises an inner surface that defines a passageway configured to accommodate a fastener and an outer surface configured to engage a structure in which the compression limiter is placed. A first retainer projects outwardly from the outer surface and includes a first retention surface that has at least a planar portion. The first retainer further includes an undercut surface disposed in inwardly from the first retention surface so as to create a corner extending in a direction with at least a component perpendicular to the longitudinal direction. A method of forming the compression limiter is also disclosed.

Abstract: A method is disclosed of forming a powder metal compact. Powder metal is placed in an annular space of a compaction die tool set in which the annular space has inner and outer cylindrical surfaces that form inner and outer cylindrical surfaces of the powder metal compact. An elastomeric tool has a first cylindrical surface adjacent to a fixed cylindrical surface of the compaction die tool set that is radially fixed and further has a second cylindrical surface, opposite to the first cylindrical surface, that touches the powder metal. The powder metal is compressed to form the powder metal compact by applying an external axial force on the elastomeric tool while maintaining the diameter of the fixed cylindrical surface so as to cause the elastomeric tool to compress the second cylindrical surface of the elastomeric tool against the powder metal.

Abstract: A powder metal cylinder liner with a ratio of the length to the wall thickness greater than 12 made of at least two end to end cylinder liner pieces with each piece having a ratio of the length to the wall thickness of less than 20. The powder metal composition includes approximately between 85% and 99% sponge iron powder, approximately between 0.1% and 2.0% graphite, and approximately between 0.1% and 2.0% ethylene bis-stearamide wax. The cylinder liner pieces can be made using conventional powder metal compaction and sintering processes.

Abstract: A powder metal component which has a powder metal composition formed into a cylinder, wherein the cylinder includes a wall thickness and a length, and a ratio of the length to the thickness is relatively high such that conventional compaction methods are difficult to use. The powder metal composition includes approximately between 85% and 99% sponge iron powder, approximately between 0.1% and 2.0% graphite, and approximately between 0.1% and 2.0% ethylene bis-stearamide wax. The powder metal component can be manufactured using an apparatus which includes a hard material core rod, and a shaped elastic die configured to circumscribe the core rod, or conversely, an apparatus with a shaped elastic core rod and a hard die.

Abstract: One or more holes that extend through a wall of a powder metal component are formed by creating an absence of powder metal in a die set during compaction at an interface between a side surface of a punch and another side surface of the die set that faces the side surface of the punch in substantially close proximity to create the absence of powder metal at the interface.

Abstract: A cast metal connecting rod of the type used in a reciprocating piston engine has a beam section between two end sections. The beam section and the end sections are integral with one another and are at least partially made of a cast metal material. At least the beam section of the connecting rod includes an insert made of a sintered powder metal material. The insert is at least partially encapsulated by the cast metal material of the connecting rod. The insert reinforces the connecting rod and can help match characteristics of surrounding or mating parts of the engine that are made of materials more similar to the material of the insert than the cast metal of the connecting rod. The cast metal material, for example aluminum alloy, of the connecting rod can also provide localized regions of high machinability where needed.