Sintered Structural Components
In many automotive, appliance, heavy machinery, and other applications, sintering is the method of choice for small, structural parts and components. Powder metallurgy and sintering are cost-effective and precise ways to enhance the strength for these load- and stress-bearing parts.
Allied Sinterings, Inc. is a leading manufacturer of small and miniature custom-engineered powder metal parts and components, with a team of expert metallurgists on staff. Learn about the properties of sintered parts, common applications, advantages of this technique, and examples of our small powdered metal structural components.
Properties of Sintered Components
Sintering is part of the powder metal manufacturing process. Depending on the requirements of the application, various powdered metals are blended to create an alloy suitable for the finished part. The powder is placed in precision molds and compacted under force to create a “green compact” that is solid enough to handle. Green compacts are then placed in a furnace at a specified interval and predetermined temperature. When they emerge from the furnace, parts are cooled and ready for any further finishing or heat treatments for hardening.
Blending multiple types of metal makes it possible to optimize the mechanical and physical properties of the finished components. Materials can be selected to enhance mechanical and fatigue strength, wear resistance, corrosion resistance, magnetism, surface smoothness, and other qualities. And because parts are formed in high-precision molds, it’s possible to hold tight tolerances and achieve minimal variation among finished parts.
Applications for Sintered Structural Components
Sintered components are used in a range of applications and industries. Examples include, but are not limited to:
Appliances
- Control levers
- Cams
- Bearings
- Hinge components
- Stators and motor components
- Gears
Automotive
- Cams
- Pawls
- Engine and transmission components
- Brake components
- Connecting rods
Industrial
- Rollers
- Cams
- Gears
- Hinges
- Plates
- Pump components
Benefits of Sintering for Structural Components
Powder metallurgy and sintering offer numerous advantages for structural and load-bearing parts, such as:
- Reduced tool costs compared to stamping or casting, and less expensive than machining individual parts
- High-precision molding achieves tight tolerances
- Less waste and scrap throughout the molding and compaction process
- Molding allows for part complexity
- Sintering creates metallurgical bonds for increased structural integrity
- Blending powder metals optimizes mechanical properties
- Structural PM components have porosity which lend themselves to oil impregnation and self lubrication
- High repeatability and efficiency for low- to high-volume production from thousands to millions
- No need for draft angles in molds or to plan for the possible effects of shear on finished parts
Case Studies About Our Sintered Components in Various Industries
Allied Sinterings works with customers in many industries. Here are some case studies that illustrate our capabilities:
Award-Winning Powdered Metal Bevel Gear Design
This metal bevel gear for disposable instruments was made with 304 stainless steel and a consolidated design that reduced costs by 45%.
Award-Winning Powdered Metal Planetary Gearset
This self-contained, single-stage gearset made from nickel and alloy steel was manufactured for a lighting system with tight tolerances and quiet operation. This won the grand prize in the PM Design Excellence Awards.
Meeting Extremely Tight ID Tolerances in Electric Vehicle Parts
We produced a pinion gear design with inner diameter tolerances that are 7/10ths of the typical tolerance needed.
Custom Tungsten/Brass Counterweights for Analog Dashboards
Here, we eliminated lead from needle indicator counterweights by creating a safer powdered brass and tungsten component with identical functionality.
World-Class Quality Assurance for Sintered Components
We have built a reputation as a leading manufacturer of custom powder metal products through several quality assurance practices including:
- High-quality materials and powder metals
- Fully calibrated process monitoring systems
- Computer-supported S.P.C.
- Density checking
- Red line gear checking double flank machine
- Environmentally controlled facilities to maintain accurate measurements
- Extremely tight tolerance capabilities
- AGMA Quality Guarantee
- Hardness testing
Superior Sintered Structural Components from Allied Sinterings
Powdered metal is among the most cost-effective ways to manufacture precision parts with high strength and tight tolerances, and Allied Sinterings has over 50 years of experience with this process. We are committed to efficient and reliable manufacturing to provide customers with the parts they need, when they need them.
Learn more about us and our products, or contact us to discuss your application.
