Abstract
The majority of automotive components for which parts with densities up to about 7.0 g/cm3 are suitable have already been converted to PM and there are few opportunities for growth in this density range. In order to meet the requirements of more demanding applications there has been a trend toward higher densities through the use of infiltration, double pressing/double sintering, or powder forging (1–4) to produce parts such as synchronizer hubs, crankshaft sprockets, planetary gear carriers, connecting rods, etc. While powder forging has been shown capable of producing parts which are superior to wrought or cast products process economics have limited market penetration by this technology (5). The double press and sinter route also adds process costs and is probably too expensive for other than premium applications. There is a real need for a systems approach that will permit double pressed and sintered or infiltrated performance characteristics to be achieved by means of single compaction processing.
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