These stainless steel parts have a minimum density of 6.7g/cm3 , an ultimate tensile strength of 50,000psi (340MPa) and give an estimated cost savings of 80% over other forming methods such as machining. Secondary operations are limited to tapping and burnishing.
The two-level, very small, thin parts require uniform density throughout the cross section. The assembly consists of four P/M parts: left and right housings which are spot welded together; two guide pins are press fitted and staked into left and right P/M plates along with the assembly of the adjusting screws. The orthodontic appliance expands with the simple twist of an Allen wrench inserted into the front, a much safer procedure than with previous designs.
Electronic Lock Actuator - A copper infiltrated steel hub used in and electronic door lock. This multi-level part has a minimum hardness of RB80 and a tensile strength of 80,000psi.
"Nonferrous Grand Prize - Eight nickel-silver parts (five Class 7 gears, two pawls, one cam) used in a three-fold fire alarm box won the nonferrous grand prize, Figure 4. Fabricated by Precision Powdered Metal Parts, Inc., Pomona, California, for Gamewell Worldwide, Ashland, Massachusetts, the parts operate in a timing mechanism inside the fire alarm box, Figure 5. Made from MPIF material CNZ-1818-17, the parts have a density of 8.0g/cm^3, a tensile strength of 234MPa (34,000psi), a yield strength of 138 MPa (20,000psi) and a 90HRH hardness. Going to the P/M route offered a 50% cost savings compared to the prior methods of manufacturing - stamping and machining.
Multi-level tooling was needed to produce the cams and pawl because of the need for uniform density in the thin wall sections. The gears are concentric to +/- 0.127mm (0.005in) T.I.R. All of the parts are made using SPC with a capability index or Cpk of 1.33."
Johnson, Peter K.
"P/M Overpowers Competitive Materials." International Journal of Powder
Metallurgy May/June 2001. 45
