Abstract: A method of additively manufacturing a monolithic metal article having a three-dimensional shape is disclosed. The method involves forming a preform of the article that includes atomized metal particles bound together by a binder material. The atomized metal particles, more specifically, comprises (1) water atomized metal particles and (2) gas atomized metal particles, plasma atomized metal particles, or a mixture of gas atomized metal particles and plasma atomized metal particles. The water atomized metal particles may be contained in one portion of the preform and the gas and/or plasma atomized metal particles may be contained in another portion of the preform. The method also includes removing at least a portion of the binder material from the preform and sintering the preform to transform the preform into the monolithic metal article.

Abstract: A number of variations may include a method including providing a first powder comprising iron; compacting the first powder into a compacted powder product having a non-planar surface, wherein the compacting includes dynamic magnetic compaction or combustion driven compaction; and increasing the magnetic coercivity of at least one of the first powder or compact powder product.

Abstract: A novel combination of heat treatment steps includes the steps of carburizing a component fabricated of a medium carbon alloy steel at an elevated temperature for between three and six hours, subjecting the component to an austempering bath and holding it there for between fifteen and two hundred forty minutes and finally cooling the component to room temperature to allow martensitic transformation. These steps may be followed with cryogenic treatment to reduce retained austenite if needed. The process produces components with low distortion, high surface hardness, from HRC 56 to 62, and high surface compressive residual stress.

Abstract: A method of making a permanent magnet and a permanent magnet. The method includes using metal injection molding to mix a magnetic material with a binder into a common feedstock and injection mold the feedstock into a predetermined magnet shape. The injection molding of the feedstock takes place in conjunction with the application of a magnetic field such that at least some of the magnetic constituents in the feedstock are aligned with the applied field. After the alignment of the magnetic constituents, the shaped part may be sintered. In one form, the magnetic constituents may be made from a neodymium-iron-boron permanent magnet precursor material, as well as one or more rare earth ingredients.

Abstract: Cam lobe packs and methods of producing the same. The method uses a tool made up of an insert disposed within a sleeve such that both are responsive to a dynamic magnetic compaction (DMC) pressure source. The insert defines a substantially axisymmetric exterior surface and a cam lobe-shaped interior surface that can receive a compactable material such that upon DMC, the material is formed into the shape of the cam lobe. The sleeve is disposed about the insert and defines a substantially axisymmetric exterior surface such that an axisymmetric compaction imparted to the sleeve by the DMC pressure source forms the desired shaped cam lobe. The tool is configured such that individual tool members corresponding to one or more of the cam lobes can be axially aligned so that an aggregate interior surface is formed that defines an exterior surface profile of a camshaft being formed.

Abstract: One embodiment includes providing a first layer including a first powder material and a second layer including a second powder material over the first layer, and compacting the first powder material and the second powder material using at least a first magnetic field.

Abstract: A number of variations may include a method including providing a first powder comprising iron; compacting the first powder into a compacted powder product having a non-planar surface, wherein the compacting includes dynamic magnetic compaction or combustion driven compaction; and increasing the magnetic coercivity of at least one of the first powder or compact powder product.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: An automotive engine component and method of producing the same. The method uses dynamic magnetic compaction to form components, such as camshaft lobes, with non-axisymmetric and related irregular shapes. A die is used that has an interior profile that is substantially similar to the non-axisymmetric exterior of the component to be formed such that first and second materials can be placed into the die prior to compaction. The first material is in powder form and can be placed in the die to make up a first portion of the component being formed, while a second material can be placed in the die to make up a second portion of the component. The second material, which may possess different tribological properties from those of the first material, can be arranged in the die so that upon formation, at least a portion of the component's non-axisymmetric exterior profile is shaped by or includes the second material.

Abstract: A silicon steel sheet formed from a silicon steel alloy composition includes, in parts by weight, iron, carbon present in an amount of from about 0.002 to about 0.06, silicon present in an amount of from about 1.5 to about 4.0, aluminum present in an amount of from about 0.1 to 1.0, titanium present in an amount of less than or equal to about 0.03, vanadium present in an amount of less than or equal to about 0.005, and cobalt present in an amount of from about 0.001 to about 5.0 based on 100 parts by weight of the composition. Neither niobium nor zirconium is present in the composition. A silicon steel sheet system including the silicon steel sheet and a coating disposed thereon, and an electromagnetic machine having a magnetic core including a plurality of sheets stacked adjacent one another are also disclosed.

Abstract: A camshaft assembly may include a assembly and a shaft. The cam assembly may include a hollow structure with an interior surface and an exterior surface. A plurality of projections may be located on the exterior surface of the hollow structure. The interior surface of the cam assembly may define a recess axially aligned with at least one of the plurality of projections. At least one of the plurality of projections may define an undercut portion. The cam assembly may be coupled with the shaft.

Abstract: An automotive engine valve stem, engine valve and method of producing both. The valve includes a head and a stem joined to the head. Lightweight, high-temperature materials, such as titanium-based materials may be used to make up at least a the majority of the valve. These materials are combined with fabrication techniques that may vary between the head and the stem, where at least a part of the valve is made by dynamic magnetic compaction. While a majority of the stem may be made from a titanium-based powder material, its tip may be made of a high strength hardened material, such as a steel alloy. The valve head may be made by single press and sintering, double press and sintering, forging and machining, forging and sintering, and dynamic magnetic compaction and sintering.

Abstract: One embodiment includes compacting a powder material using at least a first magnetic field to form a compact and selectively sintering a first portion of the compact and leaving a second portion of the compact unsintered to form a component.

Abstract: A materials combination for a camshaft and follower of an engine valve train provides excellent wear resistance. The camshaft or camshaft lobes are made from a malleable cast iron and the cam followers are made from a carbonitrided 52100 or 4130 steel to provide excellent wear resistance equivalent to diamond-like coatings at greatly reduced cost.

Abstract: A camshaft assembly may include a assembly and a shaft. The cam assembly may include a hollow structure with an interior surface and an exterior surface. A plurality of projections may be located on the exterior surface of the hollow structure. The interior surface of the cam assembly may define a recess axially aligned with at least one of the plurality of projections. At least one of the plurality of projections may define an undercut portion. The cam assembly may be coupled with the shaft.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: A camshaft journal and method of producing the same. The method uses dynamic magnetic compaction in conjunction with austenitic manganese steel powder metal precursors. Journals formed along the camshaft are configured to cooperate with complementary bearing surfaces, and can be used in cooperation with one or more sensors such that the journal does not magnetically interfere with signals travelling to such sensors. The journals may also be subjected to machining, sintering or both once the dynamic magnetic compaction has been completed.

Abstract: Cam lobe packs and methods of producing the same. The method uses a tool made up of an insert disposed within a sleeve such that both are responsive to a dynamic magnetic compaction (DMC) pressure source. The insert defines a substantially axisymmetric exterior surface and a cam lobe-shaped interior surface that can receive a compactable material such that upon DMC, the material is formed into the shape of the cam lobe. The sleeve is disposed about the insert and defines a substantially axisymmetric exterior surface such that an axisymmetric compaction imparted to the sleeve by the DMC pressure source forms the desired shaped cam lobe. The tool is configured such that individual tool members corresponding to one or more of the cam lobes can be axially aligned so that an aggregate interior surface is formed that defines an exterior surface profile of a camshaft being formed.

Abstract: A method of forming a fluid barrier over a powder metal part. The method includes providing a molded powder metal part and applying a fluid impenetrable material to a designated portion of the molded powder metal part to form a molded powder metal complex. Thereafter, the method includes sintering the molded powder metal complex to where the fluid impenetrable material and the designated portion of the molded powder metal part at least partially integrate. Further, the method includes cooling the molded powder metal complex such that the fluid impenetrable material forms a fluid barrier over the designated portion of the molded powder metal part. The method may further include anodizing the fluid impenetrable material at least partially integrated with the designated portion of the molded powder metal part and forming the fluid barrier over the designated portion so as to increase wear resistance thereof.