Powder Metal Gear Manufacturing

Powder metallurgy (PM) is a popular manufacturing method for producing high-quality gears. PM is a process where metal powders are compressed and sintered to form a solid mass. PM can produce gears with complex shapes and geometries, high accuracy, and excellent surface finish.

Gears produced by powder metallurgy methods. Parts provided by Perry Tool and Research.

The PM process for manufacturing gears typically involves the following steps:

  1. Powder preparation: Metal powders of the required composition are mixed with a lubricant to aid in their movement during the pressing process.
  2. Compaction: The powder is then pressed in a die to form a green compact. The pressure applied during compaction is carefully controlled to ensure that the desired density is achieved.
  3. Sintering: The green compact is then heated in a controlled atmosphere to a temperature below its melting point. The metal particles diffuse and bond together to form a solid mass. The lubricant that was added during powder preparation is burned off during this step.
  4. Finishing: The sintered gear is then machined to achieve the final dimensions and surface finish.

PM has several advantages over traditional manufacturing methods for gears. The process is capable of producing gears with complex shapes and geometries that are difficult or impossible to produce by other methods. It is also a cost-effective way to produce small quantities of gears. The PM process is capable of producing gears with high accuracy and excellent surface finish, which are important for ensuring smooth operation and reducing wear.