POWDERED METAL GEARS

IMPUISION GEARS,HELICAL GEARS,SPROCLET WHEEL

About Powdered Metal Process

What Is Powder Metallurgy?

Powder metallurgy is a manufacturing process that involves the production of metal parts and components using powdered materials. This process allows for the creation of complex shapes and designs that may not be easily achievable using traditional manufacturing methods.
The powder metallurgy process typically involves four main steps:

  1. Powder Production: The first step is to produce fine metal powders. This can be done through various techniques such as atomization, chemical precipitation, mechanical comminution, or electrolytic deposition.
  2. Mixing: The metal powders are then thoroughly mixed with other powdered materials, such as binders and lubricants. This helps improve the flowability and compaction properties of the powder mixture.
  3. Compaction: The mixed powders are then compacted into a desired shape using high pressure. This is typically done using a die and punch setup. The pressure applied helps to fuse the powder particles together.
  4. Sintering: The compacted parts are then subjected to a high-temperature sintering process. During sintering, the parts are heated in a controlled atmosphere to a temperature below the melting point of the metal. This allows the individual powder particles to bond together and form a solid, dense structure.

After sintering, secondary operations like sizing, heat treating, and finishing may be performed to achieve the desired final properties and dimensions of the parts.

Powder metallurgy offers several advantages over conventional manufacturing processes. It allows for cost-effective production of complex parts, reduces material waste, and enables the use of a wide range of materials, including alloys, composites, and ceramics. Additionally, powder metallurgy can provide excellent control over the porosity, density, and mechanical properties of the final product. This makes it a versatile and attractive manufacturing option for various industries, including automotive, aerospace, medical, and consumer goods.

Why Powder Metal (PM) is good for the gears manufacturer?

Powder metallurgy gears, also known as sintered gears, have seen improved performance and dimensional stability due to the development of powder metallurgy technology. Synchronizer gears, oil pump gears, gear transmission devices, reducers, and engine gears are examples in the automotive industry where forged steel has shifted to powdered steel. Powdered steel, as a cost-effective alternative, can replace a large number of machined gears.

With the material develpment, especially power transmission gears in PM, it becomes increasingly important to understand how to optimize the gear flanks as well as the gear body. The next step will be power transmission gears.The gear flanks on PM gears are softer than steel gear flanks, so they can’t work at their optimal potential when crowned according to a model for wrought steel gear flanks. That’s why it’s important to optimize the material in the gear body to take advantage of the power of powdered metal. In this paper you’ll learn about implications of crowning PM gears both axially and radially, as well as gear body design possibilities. You’ll also find out more about the damping properties of steels.

The Advantage Of The Powder Metal Gear

The powder metal gear offers several advantages over traditional gears made from other manufacturing processes, such as casting or machining.

  • One-time process without secondary machining.
  • High cost-effect solution for the gear and saving much cost.
  • Custom Design as well as the Radius
  • Flexible production: helical gears, flange, and hub cluster gear
  • Harder could be choosen based on the density of the raw material

How We Produce The Powdered Metal Gears?

Precision,Strength,Qualtiy

The powder metallurgy (PM) process involves forming powdered metals or metal blends into parts and components that offer improved strength over traditionally forged alternatives with a unique combination of heat and compression. Compared to other manufacturing techniques, the process is shorter, with a primary step below: Step1:Mix the right powder for gears,emitech will choice the right material for the different usage. Step2:Compact the powder to the right shape Step3:warm the shaped profiled at the good tempertaure
         MaterialsCupric cemented steelNickel SteelLow Alloy Steel
Performance
Typical composition13Cu-0.8C-Fe2Ni-0.5C-1.5Cu-Fe0.4Mn-0.5Ni-0.6Mo-0.5C-Fe
Material stateQuench and temper from 8710CSintered stateQuench and temper from 8710CSintered stateQuench and temper from 8710CSintered state
Density(g/cm3)7.37.36.86.86.76.8
Ultimate tensile strength(kgf/mm2)80.559.566.53678.435
Tensile yield strength, residual deformation0.2%(KGF/mm2)74.940.5562872.129
Elongation(%)0.530.81.50.61
Apparent hardnessHRC 38HRB89HRC 24HRB65HRC 29HRB60
Pellet hardnessHRC58N/DHRC 40N/DHRC 44N/D
Impact strength (Charlton value, no notch)(kgf.m)0.871.41.3811.240.9
CategoryMaterial TrademarkHeat treatmentTensile Strengthσb/MPayield pointσs/MPahardness  (HBS OR HRC)
Carbon Steel35normalizing500270150~180HBS
tempering550294190~230HBS
45normalizing588294169~217HBS
tempering647373229~286HBS
surface hardening40~50HRC
50normalizing628373180~220HBS
  surface hardening  48~55HRC
35SiMntempering750450217~269HBS
surface hardening45~55HRC
40MnBtempering735490241~286HBS
surface hardening45~55HRC
20CrCarburizing hardening63739256~62HRC
20CrMnTiafter-tempering107983456~62HRC
38CrMnAlAnitriding980834>850HV
Cast SteelZG45normalizing580320156~217HBS
ZG55650350169~229HBS
Grey Cast SteelHT300 300 185~278HBS
HT350350 202~304HBS
Nodular Cast IronQT600-3 600370190~270HBS
Qt700-2700420225~305HBS
NonmetalFabroil 100 25~35HBS

Powder metallurgy gears, like other metal materials, can have their mechanical properties improved through heat treatment methods. The heat treatment methods applied to powder metallurgy gears include annealing, normalizing, quenching, tempering, as well as carburizing, nitriding, and carbonitriding. These methods can significantly enhance the mechanical properties of powder gears. However, due to the unique nature of powder metallurgy gears, the selection of heat treatment methods and process conditions cannot be entirely based on those used for dense materials. Appropriate adjustments must be made to suit the treatment of powder metallurgy gears. Otherwise, the desired effects of heat treatment may not be achieved, or even destructive results may occur. The materials mainly used for improving the performance of powder metallurgy gears through heat treatment are iron-based alloys (sintered steel).

Full Equipment

pm equipment

Press Equipment

For compacting the powder into a desired shape at high pressures.

Sintering Equipment

To heat the compacted powders at temperatures below their melting points to bond the particles together

Shape Fix Equipment

Sizing Equipment

For improving the dimensional accuracy and surface finish of sintered parts.

Steam Treatment Furnace

Steam Treatment Furnace

Primarily improve the surface properties of metal powder products, enhancing their corrosion resistance and hardness, and also improving their appearance.

Vacuum Oil Impregnation Machine

Vacuum Oil Impregnation Machine

It improves the quality of powdered metal parts by sealing their porosity, thereby enhancing their density, strength, and pressure retention capabilities.

Grinding Machine

Remove burrs to ensure part quality.

Test Equipment For Gear Production

CMM

CMM

CMM equipment is vital in PM gear production for ensuring the precision and quality of the gears, which are critical components in mechanical transmissions and industrial equipment.

Gear Measuring

Gear measuring is a critical aspect of PM gear production, as it ensures the gears meet the necessary precision and quality standards

Gear Engaging Instrument

Gear Engaging Instrument

Gear measuring instruments are essential for ensuring quality and precision by accurately assessing critical parameters like tooth profile, pitch, and thickness, which aids in quality control and process optimization.

Why Choice Emitech Powder Metal Gears?

  • Without a secondary operation, gear quality can reach AGMA Class 8
  • We do not have to shave the teeth for Powder Metal Gears, as they are pressed into a precision die
  • Gear teeth are formed in a precision die for excellent part-to-part consistency
  • Gear IDs can have splines, keyways, D-shapes, or almost any shape without costly broaching
  • The gear tooth can be formed as custom as you like, and the root radius can be formed for maximum strength fully in the precision die, no secondary processing is needed
  • Up to a 20 degree helix angle is possible for helical gears
  • Gear clusters with one piece flanges and hubs are possible
  • Depending on the density and raw material type, powder metal gears can also be case hardened
  • In applications such as Powder Metal PUMP GEAR, we can provide you with ready to use gears, fully machined to extremely close tolerances.
  • Vision Quality Components maintains the tooling for the life of the part, normally with short payback periods.

    Powdered Metal Gears

    Spur-Helical-Bevel-Pinion-Combinations-Spiral Bevel

    Children's Bike Gear
    Children's Bike Gear
    Micro Gear
    Micro Gear
    power tooling
    Power Tooling
    high torque gear pars
    High Torque Gear Parts
    high torque gear assembling
    High Torque Gear Assembling
    High Torque Gear
    High Torque Gear
    dual speed gear
    Dual Speed Gear
    autobike use gear
    Autobike Gear

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    FAQs

    Powder metallurgy (PM) is often used for gears due to the many advantages it offers over other manufacturing methods. The primary reason is that PM allows for the production of high-quality gears with complex shapes and geometries that are difficult to achieve using other techniques. Additionally, PM allows for the use of a wide range of materials, including steel, stainless steel, brass, bronze, and others, enabling gear manufacturers to create components with specific properties such as strength, wear resistance, and corrosion resistance.Another reason why PM is preferred for gears is that it can significantly reduce material waste compared to traditional machining methods. This is due to the increased ability of PM to create net or near-net-shaped parts, meaning that much less material is discarded during production. Additionally, PM has excellent repeatability, which allows for consistent quality and performance in the final product.Overall, PM is an ideal process for making gears that require high precision, strength, and durability while also minimizing waste and enabling the use of a wide range of materials.

    Powder Metallurgy (PM) is a process used for gear manufacturing that involves the following steps:

    1. Powder Production: Raw materials are first sourced to produce metal powders that match the desired end-product properties. These powders may be made through various processes, including atomization, mechanical alloying, or electrolysis.
    2. Blending: The metal powders are blended with binders and lubricants to create a mixture. The binder helps hold the powder together during the compacting stage, while the lubricant reduces friction and prevents sticking during the compacting process.
    3. Compacting: The blended mixture is then compacted into a pre-determined shape using high pressure in a die. This creates a “green” part with a specific shape but without the necessary strength.
    4. Sintering: The “green” part is placed in a furnace and heated at a high temperature, typically between 1120°C and 1250°C, causing the metal particles to fuse together. This results in a final product with the desired strength, density, and microstructure.
    5. Finishing: The finished product may require additional operations such as milling, drilling, or grinding to achieve the final shape, size, and surface finish.Using PM to manufacture gears offers many advantages, including the ability to produce complex shapes, high precision, and excellent material utilization. Additionally, PM gear manufacturing can be highly efficient and cost-effective.

    Powder Metallurgy (PM) is a process that involves the production of metal parts using metal powders. This process typically includes the following steps:

    1. Powder Production: Raw materials are first sourced to produce metal powders that match the desired end-product properties. These powders may be made through various processes, including atomization, mechanical alloying, or electrolysis.
    2. Blending: The metal powders are blended with binders and lubricants to create a mixture. The binder helps hold the powder together during the compacting stage, while the lubricant reduces friction and prevents sticking during the compacting process.
    3. Compacting: The blended mixture is then compacted into a pre-determined shape using high pressure in a die. This creates a “green” part with a specific shape but without the necessary strength.
    4. Sintering: The “green” part is placed in a furnace and heated at a high temperature, typically between 1120°C and 1250°C, causing the metal particles to fuse together. This results in a final product with the desired strength, density, and microstructure.
    5. Finishing: The finished product may require additional operations such as milling, drilling, or grinding to achieve the final shape, size, and surface finish. The resulting products created through PM exhibit a number of unique properties such as high strength, good wear resistance, excellent dimensional accuracy, and repeatable quality. PM can also produce complex shapes with fine details, which are difficult or impossible to achieve through other manufacturing processes. Powder metallurgy has applications across industries such as automotive, aerospace, medical devices, and more due to its versatility, efficiency, and cost-effectiveness.

    Powder Metallurgy (PM) is a process for manufacturing metal parts using metal powders, and it offers several advantages over other manufacturing methods. These include:

    1. Reduced Material Waste: PM enables the creation of near-net-shape parts that require less machining, which reduces material waste and minimizes the environmental impact of production.
    2. Increased Efficiency: PM can produce complex shapes and geometries with high accuracy, which often reduces the need for secondary operations, such as drilling or machining, resulting in higher efficiency and lower costs.
    3. Precision Manufacturing: PM can create highly accurate parts with tight tolerances and low surface roughness, which is beneficial to industries such as aerospace, medical devices, and automotive that require high precision.
    4. Variety of Materials: Powdered Metal can be used with a variety of materials, including iron, copper, aluminum, and titanium, enabling manufacturers to create parts with specific properties, such as strength, wear resistance, and corrosion resistance.
    5. Versatile Applications: PM has applications across industries such as automotive, aerospace, medical devices, and firearms, as it can produce high-quality components with a diverse range of properties.

    Powder Metallurgy is a cost-effective, efficient, and flexible method of manufacturing that’s ideal for creating complex parts with high precision, excellent mechanical properties, and lower material waste.

    Three advantages of Powder Metallurgy (PM) include:

    1. Versatility: PM allows for the production of complex parts with intricate shapes and geometries that may not be achievable with other manufacturing methods. Additionally, a wide range of materials can be used in PM, including steel, stainless steel, brass, bronze, and others, which enables the creation of parts with specific properties such as strength, wear resistance, and corrosion resistance.
    2. Efficiency: PM is a highly efficient process that reduces material waste by producing near-net-shape parts that require less machining. This reduces costs and minimizes the environmental impact of production. Additionally, high precision in shaping and uniformity in sintering also lends to greater efficiency and lower processing times.
    3. Consistent Quality: PM offers excellent repeatability and control over the final product’s dimensional accuracy and mechanical properties. This results in consistent product quality across production runs and eliminates or reduces the need for inspection, enhancing the final product’s value while providing assurance of reliability and durability.These advantages make PM an attractive option for manufacturers looking to produce high-quality, custom parts that are cost-effective, efficient, and with proven performance.

    Powdered steel, also known as particle metallurgy steel, has several advantages over traditional steel. Firstly, it has a more uniform composition, resulting in superior strength, toughness, and wear resistance. This is because each particle is a discrete piece of steel that can be tailored to provide specific properties depending on the intended application.
    Secondly, powdered steel can be sintered at lower temperatures, resulting in less distortion and a finer grain structure than traditional steel. This makes it easier to machine and enhances mechanical properties.
    Lastly, powdered steel allows for the incorporation of alloying elements, such as vanadium, molybdenum, and cobalt, which are difficult or impossible to incorporate into traditional steel. These elements can further improve the properties of the steel, making it more durable and resistant to corrosion.

    Powdered metal is a material made by compacting and sintering metal powders to form solid parts. The strength of powdered metal can vary depending on factors such as the composition of the metal powder used, the sintering conditions, and any secondary processing that is done to the part. 

    In general, powdered metal parts can have excellent strength properties due to the uniformity of their composition. This is because the metal powders used in the process are thoroughly mixed before being compacted, so the resulting part has a homogeneous structure with no defects or inconsistencies that could weaken it.
    Additionally, the sintering process used to fuse the metal particles together can result in grain structures that are smaller and more uniform than those found in conventionally cast or forged parts. This can enhance the strength and toughness of the part, as well as its resistance to wear and fatigue.Overall, the strength of powdered metal parts can be tailored to meet the specific requirements of a given application through careful selection of the metal powder composition and processing parameters.

    Yes, metal can be turned into powder through a process called powder metallurgy. In powder metallurgy, solid metal is transformed into fine powder particles. This process typically involves the following steps:

    • Atomization: The metal is melted and then atomized using methods like gas atomization or water atomization. This creates small droplets of molten metal.
    • Solidification: The atomized metal droplets rapidly cool and solidify into fine powder particles.
    • Collection: The powder particles are collected and further processed to achieve the desired particle size distribution and purity.
    • Consolidation: The metal powder can be compacted into near-net shape using techniques like cold pressing or isostatic pressing. This step creates a “green” part that is porous and requires further processing.
    • Sintering: The green part is subjected to high temperatures in a controlled atmosphere, causing the powder particles to bond together through diffusion. This results in a densified and solid final product.

    Powder metallurgy allows for the production of complex shapes, precise dimensions, and near-net shape parts with excellent material properties. It is commonly used in industries such as automotive, aerospace, and manufacturing, where the versatility and advantages of powdered metal components are highly valued.

    Sintered gears and machined gears are two different types of gears that are manufactured using distinct processes. Here are some key differences between them:

    Sintered Gears:

    • Manufacturing process: Sintered gears are produced through powder metallurgy, where metal powders are compacted and then sintered to form the final gear shape. This process allows for complex geometries and cost-effective production.
    •  Material characteristics: Sintered gears are typically made from powdered metals or metal alloys. The materials used can be tailored to provide specific properties such as strength, wear resistance, and heat resistance.
    • Density: Sintered gears tend to have a higher porosity compared to machined gears due to the nature of the powder metallurgy process. The porosity affects the density, strength, and dimensional stability of the gears.
    • Gear accuracy: Sintered gears may have lower dimensional accuracy and tighter tolerances compared to machined gears due to the limitations of the powder metallurgy process. However, advances in powder metallurgy techniques have improved the precision of sintered gears in recent years.

    Machined Gears:

    • Manufacturing process: Machined gears are produced by removing material from a solid block or a pre-formed blank using various machining techniques such as milling, turning, or grinding. This process offers precise control over the gear’s dimensions and surface finish.
    • Material characteristics: Machined gears can be made from a wide range of materials, including metals, plastics, and composites. The choice of material depends on the specific application requirements.
    • Density: Machined gears have higher density and lower porosity compared to sintered gears since they are solid pieces of material. This contributes to their overall strength and durability.
    •  Gear accuracy: Machined gears generally offer high dimensional accuracy and tight tolerances due to the precise nature of the machining process. They can achieve very fine tooth profiles and surface finishes.

    Choosing between sintered gears and machined gears depends on various factors such as cost, application requirements, gear complexity, and production volume. Sintered gears are often preferred when cost-effectiveness, complex geometries, or specific material properties are important. Machined gears are commonly chosen for applications that require high precision, tight tolerances, and superior surface finish.

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