Abstract
“Powder forging” is a hybrid process in which preforms made by conventional PM techniques are hot forged in closed impression dies. The process combines many of the best features of both conventionally made PM parts and hot forgings. Although the process is still in the development stages, indications are that “powder-forged” components can be produced having mechanical and physical properties equivalent to conventionally wrought steels, together with the complexity and dimensional accuracy normally associated with sintered parts.The process appears an attractive and economic manufacturing route for many components for the following reasons: Material utilization is better than in conventional forging; detail and tolerances obtainable can lead to the elimination of much, if not all, finish machining; tight weight tolerances are possible in the “as-forged” condition, which on components such as connecting rods might ultimately lead to the elimination of weight-balancing operations.The paper describes the features of the powder-forging process, and the production route is briefly outlined. Weight and machining savings are illustrated by reference to actual components made by G.K.N. Forgings Ltd. Forging load/preform density relationships are briefly mentioned, and the importance of preform design and forging-tool design emphasized. The main factors covering preform design are outlined.Examples of mechanical properties obtained on powder-forged material are quoted, and it is explained that provided powder purity is controlled these can be comparable to those of conventionally wrought steels. The economics of the process is briefly discussed, and future development possibilities mentioned.
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