Abstract: Disclosed herein is a method of that densifies spherodized granules having tungsten carbide and a metallic binder phase in a plasma, thereby producing densified spherodized granules.

Abstract: A powder mixture alloy is provided for manufacturing surface densified high carbon sintered steel articles containing iron or iron pre-alloyed powder, which has been preliminary mixed with at least 0.4 wt % graphite, lubricant and optionally at least one alloying element from the group of nickel, chromium, copper, manganese and molybdenum. Components are manufactured utilizing the alloy mixture comprising the steps of: a) compacting the metallic powder to obtain a compact; b) pre-sintering the compact at a low temperature to prevent graphite from diffusing into the iron; c) surface densifying of the pre-sintered compact to a predetermined densification depth; d) sintering under neutral gas or carburizing atmosphere; e) heat treating the sintered compact.

Abstract: The invention provides a method and apparatus for densifying the teeth of a powder metal preform gear. The die includes an aperture for receiving a body of the gear and a plurality of grooves for receiving the teeth of the gear. The grooves have a length and a variable width along the length. The grooves narrow tangentially relative to the aperture. The powder metal preform gear is urged through the die and the teeth are plastically and elastically deformed at a relatively narrow portion of the groove. After passing through the narrow portion of the groove and being compressed, the teeth can at least partially recover. The grooves defined by the die can be helical for forming a helical groove.

Abstract: A method of fabricating clutch races for one-way clutch mechanisms includes compacting and sintering a ferrous-based powder metal to near-net shape to produce a core density of between about 6.8 to 7.6 g/cc and a race surface that is near-net shape. The cam surface is cold worked in a manner that locally increases the density at the surface to develop a highly densified layer of essentially fully densified material and with a final surface finish that, after heat treatment, is ready to use in a one-way clutch application without further working. Both the inner and outer clutch races of one-way clutch mechanisms can be formed in this fashion and yield races that exhibit excellent strength, toughness, fatigue strength and wear resistance.

Abstract: A powder mixture alloy is provided for manufacturing surface densified high carbon sintered steel articles containing iron or iron pre-alloyed powder, which has been preliminary mixed with at least 0.4 wt % graphite, lubricant and optionally at least one alloying element from the group of nickel, chromium, copper, manganese and molybdenum. Components are manufactured utilizing the alloy mixture comprising the steps of: a) compacting the metallic powder to obtain a compact; b) pre-sintering the compact at a low temperature to prevent graphite from diffusing into the iron; c) surface densifying of the pre-sintered compact to a predetermined densification depth; d) sintering under neutral gas or carburizing atmosphere; e) heat treating the sintered compact.

Abstract: An iron-based sintered powder metal article for cam lobe and other high temperature, high wear applications requiring excellent net-shape stability during sintering comprises a powder metal mixture consisting essentially of, by weight, 0.5–3.0% Mo, 1–6.5% Cr, 1–5% V, and the balance Fe and impurities. These articles also have a carburized case having 0.7–1.2% C by weight. Following carburization of the case, the articles are quenched to form a martensitic matrix having a network of disbursed carbides of Cr and V. The resulting sintered articles have good mechanical strength and wear resistance and possess excellent machineability and dimensional stability.

Abstract: A method of fabricating clutch races for one-way clutch mechanisms includes compacting and sintering a ferrous-based powder metal to near-net shape to produce a core density of between about 6.8 to 7.6 g/cc and a race surface that is near-net shape. The cam surface is cold worked in a manner that locally increases the density at the surface to develop a highly densified layer of essentially fully densified material and with a final surface finish that, after heat treatment, is ready to use in a one-way clutch application without further working. Both the inner and outer clutch races of one-way clutch mechanisms can be formed in this fashion and yield races that exhibit excellent strength, toughness, fatigue strength and wear resistance.

Abstract: The invention provides a method and apparatus for densifying the teeth of a powder metal preform gear. The die includes an aperture for receiving a body of the gear and a plurality of grooves for receiving the teeth of the gear. The grooves have a length and a variable width along the length. The grooves narrow tangentially relative to the aperture. The powder metal preform gear is urged through the die and the teeth are plastically and elastically deformed at a relatively narrow portion of the groove. After passing through the narrow portion of the groove and being compressed, the teeth can at least partially recover. The grooves defined by the die can be helical for forming a helical groove.

Abstract: A method of fabricating clutch races for one-way clutch mechanisms includes compacting and sintering a ferrous-based powder metal to near-net shape to produce a core density of between about 6.8 to 7.6 g/cc and a race surface that is near-net shape. The cam surface is cold worked in a manner that locally increases the density at the surface to develop a highly densified layer of essentially fully densified material and with a final surface finish that, after heat treatment, is ready to use in a one-way clutch application without further working. Both the inner and outer clutch races of one-way clutch mechanisms can be formed in this fashion and yield races that exhibit excellent strength, toughness, fatigue strength and wear resistance.

Abstract: A wrought or powder metal gear preform is mounted for rotation about a first axis and then driven in meshing engagement with a roll forming die supported for rotation about a second axis transverse to the first axis. The roll forming die includes a helical worm thread that moves radially as well as axially across the face of the preform teeth to displace the material of the preform. In the case of a powder metal preform, displacement of the material acts to densify the teeth, whereas in the case of a wrought preform the gear teeth are burnished. The preform and roll forming die are separately driven to control densification.

Abstract: A wrought or powder metal gear preform is mounted for rotation about a first axis and then driven in meshing engagement with a roll forming die supported for rotation about a second axis transverse to the first axis. The roll forming die includes a helical worm thread that moves radially as well as axially across the face of the preform teeth to displace the material of the preform. In the case of a powder metal preform, displacement of the material acts to densify the teeth, whereas in the case of a wrought preform the gear teeth are burnished. The preform and roll forming die are separately driven to control densification.