Abstract: A method of forming a fuel injector clamp utilizing powder metal techniques is provided. A powder metal charge comprising in percent by weight, 0.6-0.9 carbon, 1.5-3.9 copper, 93.2-97.9 iron with the balance other elements, is die compacted to a density of 7.0-7.1 grams per cubic centimeter pre-sintered at 1500-1600 degrees Fahrenheit to form a powder metal blank. The powder metal blank is then lubricated and re-compacted to at least 7.3 grams per cubic centimeter and sintered at 2050 degrees Fahrenheit to form a final powder metal blank. The fuel injector clamp itself is comprised of a unitary structure of powder metal having a generally cylindrical center portion, with a first wing portion extending laterally there from and a second wing portion extending laterally there from at a 180 degree angle from the first wing portion.

Abstract: A method of forming a crankshaft bushing or similar component is provided. A compaction die is provided having an axial, generally cylindrical internal opening. An upper and a lower punch are provided with exterior surfaces corresponding to the internal opening of the compaction die. An upper core rod passes through an axial opening in the upper punch. A lower core rod passes through an axial opening in the lower punch. The upper core rod and the lower core rod each may have a generally flat external surface section. A metal powder is compacted in the compaction die by the combined action of the upper and lower punches and the upper and lower core rods.

Abstract: A compacted magnetic powder metal component assembly for use in an electrical machine is provided. Each component assembly has a top section and a bottom section. Each top section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion and a core segment at a radial edge of each winding support. Each bottom section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion, and a core segment in a radial edge of each winding segment support. The top section and the bottom section are combined to form the component assembly.

Abstract: A compacted magnetic powder metal component assembly for use in an electrical machine is provided. Each component assembly has a top section and a bottom section. Each top section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion and a core segment at a radial edge of each winding support. Each bottom section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion, and a core segment in a radial edge of each winding segment support. The top section and the bottom section are combined to form the component assembly.

Abstract: A method of forming a crankshaft bushing or similar component is provided. A compaction die is provided having an axial, generally cylindrical internal opening. An upper and a lower punch are provided with exterior surfaces corresponding to the internal opening of the compaction die. An upper core rod passes through an axial opening in the upper punch. A lower core rod passes through an axial opening in the lower punch. The upper core rod and the lower core rod each may have a generally flat external surface section. A metal powder is compacted in the compaction die by the combined action of the upper and lower punches and the upper and lower core rods.

Abstract: A compacted magnetic powder metal component assembly for use in an electrical machine is provided. Each component assembly has a top section and a bottom section. Each top section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion and a core segment at a radial edge of each winding support. Each bottom section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion, and a core segment in a radial edge of each winding segment support. The top section and the bottom section are combined to form the component assembly.

Abstract: A compacted magnetic powder metal component stator for use in an electrical machine is provided. Each stator is comprised of a plurality of stator core assemblies. Each stator core assembly forms an arcuate section of the stator core itself. Each stator core assembly is comprised of an inner shoe component, with winding guides supporting a winding, and at least one back piece and two end caps fitted to the winding on the outer radial edge of the stator assembly.

Abstract: A compacted magnetic powder metal component stator for use in an electrical machine is provided. Each stator is comprised of a plurality of stator core assemblies. Each stator core assembly forms an arcuate section of the stator core itself. Each stator core assembly is comprised of an inner shoe component, with winding guides supporting a winding, and at least one back piece and two end caps fitted to the winding on the outer radial edge of the stator assembly.

Abstract: A stator core assembly for use in an electrical machine is provided. The stator core assembly includes a plurality of core components. Each core component forms an arcuate section of the stator core assembly. Each core component is comprised of at least two core component sections, with each core component section adjacent another core component section. Each core component section is formed of a ferrous magnetic powder metal particles which are generally mutually insulated. Such ferrous magnetic powder metal particles are pressure formed into the core component section.

Abstract: A stator core assembly for use in an electrical machine is provided. The stator core assembly includes a plurality of core components. Each core component forms an arcuate section of the stator core assembly. Each core component is comprised of at least two core component sections, with each core component section adjacent another core component section. Each core component section is formed of a ferrous magnetic powder metal particles which are generally mutually insulated. Such ferrous magnetic powder metal particles are pressure formed into the core component section.

Abstract: Gears, particularly spur gears, are produced by powder metal techniques with minimal lead line error and eccentricity, which gears are preformed from powder metal, sintered, hardened and thereafter have their involute surfaces regenerated by a hard hob with a negative rake on the hob teeth to provide gears having aligned involute surfaces between adjacent gear teeth and, between each gear tooth and the gear center line.