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Author Archives: Allied Sinterings

  1. Surface Protection & Finishing with Plating for Powdered Metal Parts

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    What Is Surface Plating?

    Surface Protection & Finishing with Plating for Powdered Metal PartsSurface plating uses compatible metals to plate or surface coat ferrous and non ferrous materials. Without surface plating, raw metal goods would remain vulnerable to corrosion, scratches, and impact damage. Learn more about the different plating methods for powdered metal components and the benefits these surface coatings provide.

    Types of Plating Methods for Powdered Metal Components

    Plating methods like electroplating, electroless plating, and immersion plating each offer unique advantages such as cost-effectiveness, thickness, and compatibility with different core and surface metals. Compare these three techniques to find the right option for your next manufacturing order:

    Electroplating

    The most popular plating option, electroplating, is a simple and versatile surface plating technique. Manufacturers place the workpiece (also called the cathode or substrate) in a chemical solution of salts. They also place the anode, a positively charged electrode (typically made from the same material as the plating metal) in the chemical bath. Manufacturers then apply an external current, oxidizing the metal ions into the bath to create a new layer of metal around the workpiece.

    Manufacturers can control the process by adjusting the voltage and duration of the current, the chemical makeup and temperature of the bath, and the distance between the cathode and anode components.

    Electroless Plating

    Electroless plating also uses a chemical solution to achieve the desired plating effect. However, this method doesn’t require a current from an external power source. Instead, the bath uses a reducing agent to deposit nickel into the bath, creating a reduction of nickel ions that attach to the surface of the submerged metal workpiece.

    Electroless plating can achieve a smooth, even finish when used with metals like nickel, copper, or gold.

    Immersion Plating

    Immersion plating uses chemically inert (nobler) metals like gold, platinum, and silver to coat metal components. Manufacturers submerge the workpieces in a solution of noble metal ions. The workpiece attracts the metal ions until the entire surface is covered.

    Immersion plating only works when coating less noble metals with more noble metals, achieving an even coating on materials like copper upon completion.

    Benefits of Plating for Surface Protection on Powdered Metal Parts

    Surface plating pairs the strength and flexibility of powdered metal with the protective characteristics of specialty coatings to produce smooth, even surfaces on powdered metal parts. This results in beneficial characteristics such as:

    • Increased durability: The right surface plating can protect metal components from impact damage, abrasion damage, and other mechanical hazards.
    • Higher corrosion resistance and oxidative resistance: Surface plating does this by shielding the functional metal with corrosion-resistant alloys.
    • Reduced friction: Plating can reduce friction by creating a smoother surface texture. Our team can achieve this with a nickel and PTFE (Teflon©) coating.
    • Aesthetic finishes: Surface plating can produce a shiny or aesthetically appealing metallic surface on products.

    Applications of Plating in Manufacturing

    Manufacturers across every industry choose plating as their preferred finishing option because it offers so many benefits across diverse use cases. Some of the most popular applications for surface plating in manufacturing include:

    • Electrical components
    • Gears and other mechanical parts
    • Medical devices and implants
    • Contacts

    Plating Services From Allied Sinterings

    Metal components work best when they have a strong construction and reliable surface-level protection. At Allied Sinterings, we have the resources and expertise to achieve both. Along with manufacturing standard and custom powdered metal products, we provide surface plating and related services that align with customers’ varying project goals, product applications, and budgetary needs. We support small OEMs, Fortune 500 companies, and everyone in between with high-quality plating options for consumer goods, industrial components, medical devices, and more.

    As part of our ongoing commitment to quality and ISO 9001:2015 certification, we complete all plating services from a climate-controlled workshop in the United States, using comprehensive process monitoring and computer-supported quality assurance programs to meet or exceed the quality requirements of every project.

    Contact us today to find the right plating techniques for your products, or request a quote to start your order.

  2. ISO 13485 Compliant: Allied Sinterings’ Quality Management System for Small Medical Device Components

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    ISO 13485 Compliant: Allied Sinterings’ QMS for Small Medical Device Components

    ISO 13485 is a globally accepted standard for quality management systems (QMS) specifically intended for companies in the medical device sector. This standard provides the framework for a comprehensive QMS that ensures the quality, safety, and performance of medical devices.

    Allied Sinterings has been ISO 13485 compliant since our inception, illustrating our dedication to maintaining the highest quality standards. We have extensive experience producing superior-quality small and miniature powdered metal components that comply with strict standards for use in medical devices. Here, we’ll go over the importance of ISO 13485 and the benefits of working with a compliant manufacturer.

    Why Is ISO 13485 Important?

    ISO 13485 is critical because it ensures consistent design, production, and delivery of safe medical devices. Additionally, this standard helps to:

    • Improve risk management. ISO 13485 provides a system to identify and mitigate risks throughout the product lifecycle. This is important in ensuring both patient and user safety.
    • Comply with regulatory requirements. ISO 13485 helps companies meet stringent regulatory requirements specific to medical device manufacturing, including FDA Quality System Regulation (QSR) and EU Medical Device Directive (MDD) standards.
    • Enhance operational efficiency. ISO 13485 streamlines manufacturing processes for improved efficiency, reduced waste, and increased productivity.
    • Improve product quality. Implementing a robust QMS is key to improving product quality, decreasing defects, and minimizing recalls.
    • Increase customer satisfaction. By complying with ISO 13485 guidelines, companies demonstrate their commitment to producing safe and reliable medical devices, leading to increased customer satisfaction.

    Key Requirements of ISO 13485

    ISO 13485 outlines the requirements for design and development, production and post-production processes, and risk management for medical device manufacturers. Key requirements include:

    Quality Management System (QMS)

    To comply with ISO 13485, organizations must implement and maintain a QMS that aligns with the requirements set out in the standard. This includes general requirements as well as the documentation needed to effectively manage a QMS.

    Resource Management

    Medical device manufacturers must devote sufficient resources to managing a QMS and maintaining system effectiveness.

    Management Responsibility

    Top management must demonstrate its commitment to the implementation and maintenance of an effective QMS. This can include:

    • Establishing high-value quality objectives/policies
    • Ensuring the allocation of QMS resources
    • Conducting management reviews
    • Communicating the importance of meeting regulatory guidelines

    Product Realization

    ISO 13485 requires medical device manufacturers to adequately plan their product realization efforts. This includes:

    • Establishing product quality requirements
    • Defining the required production processes and documentation
    • Outlining employee training and qualification requirements
    • Establishing processes for validation, verification, monitoring, measurement, inspection, storage, handling, traceability, and distribution

    Measurement, Analysis, and Improvement

    Medical device manufacturers must develop procedures for monitoring and measuring product success. This includes handling complaints, conducting internal audits, reporting incidents to regulatory authorities, continuously evaluating processes and products, identifying and managing nonconforming products, and analyzing data for ongoing improvement.

    Benefits of Working With an ISO 13485-Compliant Manufacturer of Powdered Metal Components

    Medical Components

    Working with an ISO 13485-compliant manufacturer like Allied Sinterings offers numerous benefits, including:

    • Opens doors to new customers and markets, particularly those in regulated industries
    • Increases credibility and highlights a proven commitment to quality and compliance
    • Improves productivity and efficiency by streamlining processes and reducing waste
    • Enhances risk management, helping to avoid costly product recalls and legal issues
    • Promotes customer satisfaction and loyalty

    ISO 13485-Compliant Miniature Powdered Metal Parts From Allied Sinterings

    Allied Sinterings manufactures a wide range of miniature powdered metal parts for medical devices, including planetary gear drives, fine pitch gears, structural components, timing gears, and several varieties of custom gears. As an ISO 13485-compliant company, we strive to maintain strict quality assurance practices and deliver consistently high-quality products that meet our customers’ needs.

    For more information about our products and capabilities, contact us or request a quote today.

  3. Benefits of Carbide for Tooling

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    Carbide tooling for manufacturing powder metal partsCarbides are compounded metals made by blending carbon with other metals or semi-metals. In manufacturing applications, such as stamping, drilling, and cutting, tungsten carbide is a common choice for tooling. It combines the properties of both materials, resulting in high-strength tools that are wear and heat-resistant, extremely hard, and highly durable over time. In fact, carbides can be up to three times stronger than steel and as strong as diamond.

    Here, you’ll learn more about the benefits of carbide metals used to manufacture tooling for operations like cutting, milling, drilling, punching, and reaming.

    Advantages of Solid Carbide Tooling

    Carbide has several advantages over other materials, such as steel, for tooling:

    Improved Tool Life and Durability

    Solid carbide has superior wear resistance and overall hardness than traditional materials used for tooling. The result is cutting tools that hold their dimensions and edges for longer, create higher-precision parts, and need to be replaced far less frequently than tooling made from steel or other materials.

    Increased Heat Resistance

    Carbide is highly heat-resistant, which is beneficial for high-speed cutting and material removal applications that generate high temperatures. Carbide also dissipates heat efficiently, which helps avoid overheating, wear, and breakage.

    Reduced Tool Deflection

    Because it is rigid and strong under pressure, carbide minimizes push-off and deflection when tools are pressed on a workpiece or raw material. This improves accuracy and precision in cutting and material removal, which reduces waste.

    Cost-Effectiveness of Solid Carbide Tooling

    Manufacturers frequently use solid carbide tooling because it is cost-effective to produce using powder metallurgy and sintering processes.

    Long-Term Savings

    Because tools made from carbide have a long service life and hold their dimensions and edges for longer, they save on tool replacement costs and the associated downtime or dips in productivity.

    Improved Production Efficiency

    As a highly heat-resistant material, carbide can be used for high-volume and high-speed cutting and stamping operations. This helps maintain efficient production without risking damage to tooling or the components being manufactured.

    Carbide Metals in the Tooling Industry

    Carbide metals, such as tungsten carbide, are a popular choice for tools used for many cutting, drilling, stamping, drawing, and reaming operations.

    Carbide Tooling

    The strength, hardness, and wear resistance of carbide tooling contribute to faster cycle times and the ability to hold tight tolerances over time. Carbide also tolerates temperatures without cracking or other damage, keeping tooling intact and functional for longer.

    Thanks to their long lifespan and cost-effective powder metallurgy manufacturing process, carbide tooling products will ultimately save money in the long term.

    Benefits of Carbide Tools

    There are multiple benefits of choosing carbide tooling over those made with other metals, including:

    • Affordable powder materials and precision blending to meet customer requirements
    • Wear resistance at extreme temperatures and high operating speeds
    • Superior overall durability for increased service life
    • Hardness contributes to lasting sharpness and dimensional stability

    Use in the Tool and Die Industry

    Carbide tooling is used in many tool and die and material removal applications. Some examples include, but are not limited to:

    • Cutting and shearing
    • Blanking
    • Punching
    • Drawing
    • Hole reaming
    • Turning
    • Milling
    • Drilling
    • Injection molding components
    • Thread and wire dies
    • Casting tools

    Carbide is a material of choice in these and other applications because it stands up to the extreme temperatures, forces, and pressures that accompany high speed operations. As a result, tools last longer, cycle times are maintained, and productivity stays on track.

    Contact Allied Sinterings About Your Powdered Metal Projects

    Allied Sinterings specializes in powder metallurgy manufacturing, where we use carbide metal tooling for the manufacture of parts and components used in small or miniature applications. We work with small and large OEMs in the industrial and manufacturing, medical, industrial, commercial, and consumer products industries.

    Contact us today for more information about our capabilities or to request a sample.

  4. Powder Metallurgy vs. Metal Injection Molding

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    Powder Metallurgy vs. Powder Injection MoldingThe metalworking process is indispensable in the production of critical components across diverse sectors. As industries evolve, there is a growing demand for custom-engineered powder metal products. This emphasizes the need for advanced manufacturing methods, including powder metallurgy and metal injection molding.

    Selecting the appropriate metalworking technique is paramount in achieving optimal results and ensuring that the components align with the demands of their application. This article will explore the intricacies of metal powder injection molding and powder metallurgy to help you choose the right process for your specific applications.

    The Powder Metallurgy Process

    Powder metallurgy utilizes metal powders as the starting raw material. They are produced through various methods such as atomization, mechanical comminution, or chemical processes. The chosen raw material is then blended with additives to improve properties like flowability and ease of compaction. Next, the powder blend is compacted using a die and press, creating a green part that is subjected to high temperatures during sintering. This causes the metal compact to molecularly bond, creating a strong sintered component.

    This metalworking technique excels in crafting complex shapes, particularly small gears and miniature parts for planetary drives. Its ability to mass-produce intricate elements cost-effectively enhances the efficiency of these drive systems. The process is also used for producing consumer products and components in the medical field.

    Moreover, powder metallurgy is a resource-efficient method that generates minimal material waste. Its flexibility in processing various metals and alloys allows manufacturers to tailor materials to specific application requirements.

    The Metal Injection Molding Process

    Metal injection molding (MIM) combines the principles of plastic injection molding with powdered metallurgy to produce complex-shaped metal parts.

    The process begins with blending metal powders and a binder to create feedstock. Then, the mixture is injected into a mold cavity using a molding machine. Post-molding, the part undergoes debinding removing the binder from the green part via thermal or solvent methods. The debound part is then subjected to high temperatures in a controlled atmosphere during sintering. The metal powder particles fuse while the remaining binder is removed, leaving a fully dense metal part with the desired shape.

    MIM-produced components exhibit improved mechanical properties than traditional methods, thanks to fine powder particles and precise sintering that enhances strength and hardness. In addition, the controlled injection molding process ensures tight tolerances and uniformity across numerous components, offering remarkable consistency. It is also cost-effective for mass-producing small, intricate parts precisely, making it ideal for aerospace, automotive, medical, and electronics applications.

    Powder Metallurgy vs. Metal Injection Molding

    Powder metallurgy and metal injection molding share a common starting point metal powders. However, their fundamental differences arise in handling these powders and the subsequent manufacturing processes.

    Precision and size limitations are also key distinctions between the two processes. While versatile in accommodating various sizes, powder metallurgy may face challenges in achieving high precision. Thus, it often requires additional machining for intricate features. On the other hand, MIM is renowned for its precision capabilities. It can produce near-net shape components with intricate details.

    Additionally, powder metallurgy is well-suited for a broad range of sizes and high-volume production scenarios, making it the more cost-effective choice for mass production. Conversely, MIM is most applicable for small to medium-sized components with complex geometries. This makes it particularly advantageous for applications demanding intricate details and moderate to high production volumes.

    Ultimately, the choice between powder metallurgy and MIM hinges on specific part requirements and key factors such as precision, size, cost and production volume.

    Allied Sinterings: Your Trusted Manufacturer of Miniature Powdered Metal Products

    Allied Sinterings is an industry leader in producing small powdered metal products. We excel in producing small gears and miniature components for planetary devices, as well as assemblies and subassemblies for various commercial and consumer products. All parts undergo processing in a climate-controlled environment and are subjected to a rigorous quality assurance system to ensure the highest standards.

    Contact us to discuss your projects! You can also request a quote to get started.

  5. Sintered vs. Machined Gears

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    Sintered vs. Machined Gears

    Gears are interlocking mechanical components that transmit motion and power between rotating shafts. They are essential in various machines and systems because they alter mechanical energy’s speed, torque, and direction. These parts also come in different shapes and sizes, each tailored for specific applications. They are often indispensable in automobiles, appliances, or industrial machinery.

    This article will provide a comprehensive comparison between sintered and machined gears, exploring their respective applications, advantages, and disadvantages.

    Sintered Gears

    Sintered gears are produced through the powdered metal (PM) method, involving a specific sequence of steps. First, metal powders are thoroughly mixed, followed by the compaction of the materials into the desired shape and size for the gear. Subsequently, the compacted form undergoes controlled heating at specific temperatures.

    This methodological approach to gear manufacturing ensures a robust end product, making sintered gears suitable for various applications. Their strength and durability stemming from the fusion of metal particles make them particularly advantageous in situations prioritizing reliability and resilience. This attribute contributes to their extensive utilization across various mechanical systems and devices.

    Sintered Gear Applications

    Here are the most common applications of sintered or powdered metal gears:

    • Automobiles
    • Power tools
    • Medical instruments
    • Domestic appliances
    • Outdoor power equipment
    • Marine equipment

    Machined Gears

    Machined or precision gears are crafted using a procedure that involves cutting a gear shape with specialized machines. Common gear-cutting processes include hobbing, grinding, and milling. These three methods enable exact control over gear size and tooth profiles, resulting in high accuracy. The method choice depends on the gear design’s complexity and the desired precision level.

    CNC machining stands out as a preferred method for engineers seeking extreme precision and accuracy in gear manufacturing. It involves utilizing computer-controlled machines to execute precise and complex cuts. This technology enables the creation of gears with intricate designs and tight tolerances, meeting the demands of industries requiring precise gear engagement.

    Machined Gear Applications

    Listed below are the common applications of machined gears:

    • Factory automation tools
    • Packaging machines
    • Industrial robots
    • Food processing machinery
    • Machine tools
    • Material handling tools
    • Printing machines
    • Automatic cutting/welding machine
    • Medical/cosmetic apparatus
    • Construction machines
    • Wood/glass processing machine
    • Agricultural machinery

    Sintered vs. Machined Gears: Advantages and Disadvantages

    This section compares sintered and machined gears based on the following factors:

    Production Costs

    Sintered gears often have lower production costs than machined components due to the efficiency of the powdered metal process. Meanwhile, precision gears are often used for projects with extremely tight tolerances, so they tend to be more expensive.

    Production Time

    The sintering process is typically faster than machining since it involves fewer steps. This quick turnaround makes it suitable for industries with high-volume production needs. Conversely, the multi-step machining process may extend production time, especially for intricate designs or large quantities.

    Precision

    Machined components are often preferred for industries requiring micron-level precision for their exceptional accuracy. Nonetheless, sintered gears can also produce tight tolerances and intricate designs, making them ideal for mass production in various industries.

    Strength

    Sintered gears are known for their strength and durability, making them highly suitable for heavy-duty applications. Meanwhile, machined components may also be suitable in situations where the highest load-bearing capacity and precision are critical.

    Quality

    Precision gears consistently meet the high-quality standards of sectors demanding precise and reliable performance. On the other hand, sintered gears deliver exceptional quality for applications with more emphasis on manufacturing timeline, cost-effectiveness, and durability.

    Scrap Waste

    Sintering is an efficient process with minimal material waste. Likewise, machining produces less waste than other manufacturing processes, contributing to efficient material utilization. Despite the efficiencies of both techniques, some scraps may still occur during manufacturing operations.

    Design Flexibility

    Machined gears are capable of achieving highly complex and specialized designs. Similarly, sintering allows for reasonably intricate designs, making it suitable for various gear shapes and sizes.

    Self-Lubrication Capabilities

    Precision gears allow customized lubrication based on specific project requirements. On the other hand, sintered gears can possess inherent self-lubricating properties due to the material’s porous structure. This reduces the need for external lubrication in certain applications.

    Ability To Be Impregnated With a Variety of Materials

    Sintered gears can be impregnated with different materials to improve specific characteristics. Similarly, machined components can be coated with various compounds to enhance their mechanical properties, providing customization options.

    Volume Repeatability and Overall Cost

    Sintered gears offer cost-effective production but may have lower volume repeatability due to variations in the sintering process. On the other hand, machined gears provide superior volume repeatability. This ensures consistent performance but comes with a higher overall cost attributed to the machining process.

    Choose Allied Sinterings for High-Quality Gear Products

    Allied Sinterings is a globally acknowledged leader in producing custom-engineered powder metal products tailored for small-scale applications! We specialize in manufacturing small gears and miniature components designed for planetary drives. This showcases a commitment to precision and innovation in gear technology.

    Contact us today to learn more about our capabilities or request a quote to get started with us!

  6. How To Find the Right Sintered Metal Parts

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    Sintered metal components begin as powder compacts heated in a furnace to fuse the grains, forming hard, usable finished products. These intricate and complex-shaped parts are prevalent in multiple industries, including aerospace, agricultural, automotive, electronics, medical, and consumer goods.

    The sintering process works with various metals and alloys and is frequently used to produce many part types. However, finding the appropriate sintered components can be challenging, and those who purchase or use them should be familiar with the technique.

    This article will discuss the advantages of sintering and several tips for finding the right sintered metal parts for your application.

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    How To Find the Right Sintered Metal Parts

    Benefits of Sintering

    Sintering is the process of applying heat to a formed component. After it has been completed, the metal particles are fused, and the structural rigidity of the element is attained.

    In addition to transforming metal powder into a solid mass, sintering also provides the following benefits:

    • Allows for the fabrication of metal components with high levels of repeatability
    • Creates highly complex shapes
    • Is cost-effective, particularly when fabricating large quantities of metal parts
    • Manufactures components with high magnetism and porosity
    • Enables manufacturers to produce large quantities of parts with tight tolerances
    • Increases the metal part’s durability
    • Generates minimal waste, with roughly 97% of the starting material used to create a part
    • Reduces production costs due to less waste

    Tips for Finding the Right Sintered Metal Parts

    Over the years, sintering has become one of the most prevalent metal-forming processes. However, given the market’s abundance of manufacturers producing sintered metal parts, selecting the most suitable one for your project can take time and effort.

    Here are four tips to guide you in finding the right metal parts:

    Identifying the Application of the Metal Part

    Sintered metal products apply to various industries and applications. Therefore, it is essential to determine where the metal component will be utilized or what part must be sintered.

    Here are some of the common uses of metal sintering:

    • Armatures
    • Bearing retainers
    • Brackets
    • Cams
    • Couplings
    • Custom bearings
    • Electrical contacts
    • Gears
    • Levers
    • And many others!

    Selecting the Best Material for Sintering

    A wide variety of metals can be sintered to create various products and parts that meet the exact requirements of a project. Furthermore, powders can be combined to create unique and durable alloys.

    Common materials used for sintered components include:

    • Carbon steel
    • Copper and copper alloys
    • Hardened steels
    • Iron-copper alloys
    • Iron-nickel alloys
    • Low-alloy steels
    • Nickel steel
    • Soft magnetic alloys
    • Stainless steel
    • And more!

    Determining the Need for Secondary Processing

    In some instances, a sintered metal part must be modified by secondary processes to improve its characteristics. For example, Gear rolling for higher tooth density and tolerance control. Copper infiltration for  improved strength of components. Oil impregnation for lubricating properties and corrosion resistance. Steam treating for sealing and corrosion resistance. Various plating for improved surface properties or sealing parts for critical applications. Machining for more complex designs or features not able to be originally compacted.

    Parts that have been sintered may also undergo tempering, , deburring, machining, and sizing as secondary processes. Particularly, sintered components with extremely tight tolerances — such as bushings and bearings — are frequently subjected to secondary sizing procedures.

    Partnering With a Reliable Powder Metallurgy Manufacturer

    A powder metallurgy manufacturer will always adhere to the customer’s specifications. However, involving your manufacturer in the design process could significantly optimize your component.

    In addition, reliable powder metallurgy manufacturers can steer you toward reasonably priced, high-performance sintering options. They can also help reduce manufacturing costs without compromising the performance of your metal part.

    Allied Sinterings: Your Trusted Custom Manufacturer of Powdered Metal Products

    Allied Sinterings has provided high-quality powdered and sintered metal products to our customers in various industries for over six decades! We take pride in our long-standing business relationships and reputation as a dependable company.

    We are the first company in our industry to obtain ISO 9000 certification, and we continue to utilize our accreditation as a valuable business tool. For more information, contact us today, and we will be happy to assist you with your needs.

  7. What Is Sintered Powdered Metal?

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    Powder metallurgy involves using metallic powders to produce finished or semi-finished shaped components. It is becoming an increasingly popular option for traditional casting to create application-specific metal parts.

    However, while the compaction process performs most of the work, Compacting pressures will only attain up to about 90% of theoretical densities. PM compacting is a net shape or close to net shape process. Here is where sintering comes into play.

    In this article, we will delve into the fundamentals of the sintering process in powder metallurgy, including its definition, benefits, and applications.

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    sintered powdered metal

    Definition of Sintering

    Sintering is used to provide strength and a stabilizing agent to a material. The sintering of powdered metals is a process in which particles Physically bond under pressure to create a cohesive “green” shape and  when subjected to sintering temperature compacted particles then bond. Typically, the temperature at which the particles are sintered is below the melting point of the powder’s primary material.

    Before the actual sintering process, choosing a powder composition that will produce the desired results is crucial. The powder mixture will contain essential elements — such as copper, iron, molybdenum, and nickel — plus other substances like lubricants and flow enhancers. These will help in improving the powder’s flow into the die. Then, the powder is pressed with extreme force and high pressure to fuse it.

    After the powder has been compacted, the sintering process begins by transferring the parts through a highly controlled Hydrogen/ nitrogen atmosphere  furnace . The objective is to maintain a temperature just below the melting point of the metal, but not completely. Finally, the sintered components are prepared for additional finishing and or secondary heat treatments to achieve the desired properties.

    Benefits of Sintered Powdered Metal Products

    Sintering enables manufacturers to replace costly metalworking techniques — such as cutting, casting, and stamping — with a more economical alternative. Here are some additional benefits of sintered powdered metal products:

    • Environmentally friendly
    • Excellent tolerance control
    • Good performance properties in parts
    • Superior surface finishes
    • High levels of uniformity and purity
    • Reduced costs due to minimal material waste
    • Sound dampening
    • Self lubricating

    Applications of Sintered Powdered Metals

    Sintering has a wide range of applications in various industries. For example, sintered stainless steel is utilized as filtering material in applications requiring high thermal stability and the ability to regenerate the filter component. On the other hand, sintered silver and gold are frequently used to create small jewelry items.

    This process is also one of the few feasible manufacturing techniques for metals with low melting points, including bronze, copper, molybdenum, tungsten, and osmium. Particularly, sintered bronze is used as a bearing material due to its porosity, enabling lubricants to flow through or remain trapped within it. Meanwhile, sintered copper is used as mainly heat sinks and corrosive environments

    Sintered powdered metals are also utilized in the military and defense industries. Artillery and grenade launcher detonators and timers.  The process also works well for net shape gun parts such as front and rear sights. Sporting rifles contain many PM components due to there quality and reliability

    Allied Sinterings for Quality Powdered and Sintered Metal Parts

    Since 1959, Allied Sinterings has provided powdered and sintered metal products using powders and materials of the highest quality. Our proficiency with complex and intricate geometries enables us to serve numerous industries, including the automotive, medical, telecommunications, and industrial equipment sectors.

    Contact us today to learn more about our capabilities or request a quote to get started with Allied Sinterings!

  8. Key Considerations in Choosing Powdered Metal Parts

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    Powdered metal parts are made using powder metallurgy. They have various applications in different industries, including automotive, aerospace, medical, and industrial. In manufacturing, they are typically used for gears, bearings, bushings, cams, and other precision components.

    One of the main advantages of powdered metal parts is they can be produced more efficiently than traditional cast or machined parts. They also can be created in large quantities, with consistent properties and performance.

    There are many advantages to using powder metallurgy, but is it the best solution for your project? This article will explore the pros and cons of powder metallurgy and the key considerations in choosing powdered metal parts for your manufacturing requirements.

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    Key Considerations in Choosing Powdered Metal Parts

    Things To Remember When Choosing Powdered Metal Parts for Manufacturing

    There are several factors to consider when choosing powdered metal parts to ensure that your components are high-quality and perform according to design expectations. These include the following:

    Material Compatibility

    Not all metals can be treated using powder metallurgy. Therefore, it is important to confirm whether the material you select is workable. The best materials for producing powdered metal components are nickel, cobalt, titanium, iron, steel, Stainless Steel, copper, bronze, and aluminum.

    Precious metals like gold, silver, platinum, and palladium are also used in powder metallurgy. They have excellent electrical conductivity and corrosion resistance. Further, they are non-toxic, making them suitable for electronic applications.

    Mechanical Properties

    The mechanical characteristics of powdered metal parts — such as strength, ductility, and wear resistance — may not always meet the application’s requirements. Choosing a powdered metal part with unsuitable properties can lead to failure or reduced performance in your components. However, PM can cost-effectively meet most of these requirements or 90% of like wrought material

    Design Flexibility

    Although powder metallurgy enables the production of parts with intricate geometries and custom holes, keyways, or stepped cores, it may not always meet the application’s design specifications. Therefore, when selecting a powdered metal component, it is best to know all your project requirements and decide on them.

    Tolerance and Finish

    Powder metallurgy may or may not be able to produce parts with very tight tolerances or that require a high surface finish. Thus, ensure that the powdered metal part’s dimensional tolerance and surface finish meet your application’s requirements.

    Cost

    Powder metallurgy can be a cost-effective manufacturing method. Still, it is important to consider the investment necessary for the powders, handling and processing, and the total cost of production before going through this manufacturing technique. Tooling is low-cost compared to other tooled processes.

    What To Look For in a Powder Metal Distributor

    There are several industry-specific characteristics and qualifications to look for to ensure that you are working with a reputable and reliable powder metal molder. Among them are the following:

    Highly Recommended by Industry Leaders

    A supplier with a good reputation in the industry is likely to be reliable and provide high-quality products and services. You can ask other manufacturers in your industry for recommendations or research suppliers online to get an idea of their track records. Typically, a dependable and experienced powdered metal supplier can also provide references from other established manufacturing companies.

    Excellent Customer Service

    Look for a distributor who can provide technical support and guidance throughout the process, from material selection to production and delivery.

    Timely Delivery and Handling

    The manufacturer you work with should be able to provide the materials you need promptly so that you can meet production deadlines. Late deliveries can cause delays in production and lead to lost revenue. On the other hand, when goods are supplied on time, they are easily managed and distributed.

    High Safety Standards

    A supplier that adheres to the highest safety standards will ensure that the materials they provide are reliable. This can help protect your employees and customers and reduce liability risks.

    Get Your High-Quality Powdered Metal Parts From Allied Sinterings!

    Allied Sinterings understands the importance of working with a reliable powdered metal supplier. We adhere to the highest industry standards, safety, and quality to maintain our brand’s impeccable reputation and ensure customer satisfaction.

    Contact us for all your powdered metal components needs!

  9. Understanding the Powdered Metallurgy Process

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    Powder metallurgy involves heating compacted metal powders just below their melting temperatures to create hardened Net Shape geometries. It is the best method for producing high-quality parts for numerous significant applications.

    The popularity of powder metallurgy can be attributed to the advantages the technique has over conventional metal forming processes like forging and metal casting. These benefits include better material utilization, increased shape complexity, and improved near-net-shape dimensional control. Additionally, this method is renowned for promoting sustainability.

    Powder metallurgy has several advantages over other techniques. Enhanced product quality, shape and material flexibility, application variety, and cost-effectiveness impact the part-to-part homogeneity of components produced through this method.

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    Understanding the Powdered Metallurgy Process

    The Powdered Metallurgy Process

    Powder metallurgy is a process that creates precise and accurate parts by applying a range of pressures to press powdered metals and alloys into a hard tooling . Here are the four fundamental processes in this technique:

    Powder Preparation

    All metals and alloys can be reduced to a powder, regardless of the method utilized. For instance, various techniques can be used to create non-ferrous metal powders in different applications. Meanwhile, almost all iron powders used in producing powder metallurgy structural parts are produced either by the sponge iron method or water atomization.

    Aside from atomization, other procedures for creating powder include chemical reduction, electrolytic deposition, and atomization.

    Mixing and Blending

    To ensure the finished product has the required properties, powders are mixed and blended with other powders, binders, and lubricants. Depending on the item’s specifications, this can be wet or dry. Further, adding alloys and a pressing lubricant is usually included in this process.

    Compacting

    Compressing the powder mixture into the required form or tooling is known as compacting. When done correctly, compacting reduces potential voids and greatly boosts the product’s density.

    Each type of metal powder requires a particular compacting pressure — from 80 MPa to 1600 MPa — depending on its characteristics. For example, the pressure for compacting soft powder ranges from 100 MPa to 350 MPa, while the pressure ranges from 400 MPa to 700 MPa for harder, more resilient metals like steel and iron.

    Sintering

    In this step, the material is heated to a temperature below the melting point of the main component, typically in a protective environment. Liquid phase sintering refers to situations where a minor constituent can occasionally form a liquid phase at the sintering temperature.

    Components Manufactured Using the Powdered Metallurgy Process

    Powder metallurgy may be used to meet the requirements of any application or production process, and almost all manufacturing companies use it. Among these applications includes areas in the industries below:

    Automotive Gears

    The capacity to generate complex configurations utilizing efficient production techniques is one of powder metallurgy’s benefits for producing vehicle parts. Finishing or machining are unnecessary if complex components can be produced without waste or scrap.

    Machinery Gears

    When it comes to powder metallurgy, one of the most frequently produced items is gears. This process provides outstanding precision, extending gears’ life. Champhers and various techniques can be used to localize density,increase strength and improve smoother outcomes. .Compound gears can be made net without separate gears or assemblies.

    Oil and Gas Industry

    Exploration for gas and oil requires hard metal and diamond-cutting equipment. Powder metallurgy creates tools from austenitic and stainless steels to fill this need.

    Powdered and Sintered Parts From Allied Sinterings

    Since 1959, the knowledgeable staff of Allied Sinterings has produced reliable and high-quality powdered and sintered metal goods. Our proficiency with complex and intricate geometries using top-notch powders and materials is well-known and appreciated among clients in the telecom, automotive, medical, and industrial equipment industries.

    Experience world-class services from Allied Sinterings! Contact us today.

  10. Gearing Types and Applications

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    Gears are essential components in many mechanical systems, especially in transmitting power and motion from one rotating shaft to another. They come in various shapes and sizes, each with its unique set of advantages and disadvantages. Particularly, mechanical gears are utilized to increase productivity and reduce costs. Some applications include assembly lines, robots, conveyor belts, and packaging equipment.

    This article will discuss the uses of gears in common manufacturing applications and custom gears used in niche industries with high-end requirements.

    How Gears Work

    Gears transmit torque by interlocking, facilitating the transfer of rotational force from one unit to the next. They function as a pair and are connected to a shaft or the base part of a machine. Additionally, the ratio between two interlocking gears is established by their number of teeth.

    If the driving gear (input) is greater than the number of teeth on the driven gear (output), the output will rotate at a slower speed but with greater torque. Conversely, if the driving gear has few teeth, the output turns faster with less force.

    Specialized Types of Gears and Their Applications

    Allied Sinterings specializes in producing small, precision-made gears for various applications. These custom gears are used in multiple industries, such as Medical devices, robotics, and electric vehicles (EVs). Here are some of the most commonly used specialized components:

    Actuator Gears

    Electric vehicle actuator gears are mechanical components used to control the movement and positioning of different parts in an electric vehicle. They are typically precision-engineered and designed to withstand the high loads and stress in EVs.

    Planetary Gears

    Planetary gears are a type of gear system consisting of sun, planet, and ring gear. They are designed to provide high gear ratios in a compact space and are widely used in automobiles. Moreover, their unique design allows multiple gear ratios within a single system, making them a versatile and efficient power transmission solution.

    Harmonic Drive Gears

    The harmonic drive gear system is distinguished by its unique design, which enables high precision and accuracy in a compact size. This makes it a popular option for applications requiring high precision, such as robotics, semiconductor manufacturing, and aerospace.

    One of its advantages is its ability to achieve a high reduction ratio in a smaller package. This is particularly beneficial for applications where space is limited. In addition, it has a high torque and a low backlash, which is the minimal amount of play or looseness between the gears.

    Spur Gears

    Spur gears are characterized by their straight teeth and are the most commonly used type in medical devices. They are typically used to power surgical instruments, pumps, and other mechanical systems. In addition, their simple designs are easy to manufacture and maintain, making them an ideal choice for applications requiring reliability and durability.

    Stepper Motor Gears

    Stepper motor gears enhance the performance of stepper motors by improving their torque and precision. These gears are precisely manufactured to complement the control capabilities of stepper motors. They also regulate the movement of the device’s various components — such as wheels, actuators, and mechanical systems — to ensure accurate and controlled motion.

    Shift Gears for Wire Systems

    Shift gears for wire systems are mechanical or hydraulic components used to control the speed and torque of the wiring system output. They can also be controlled manually or automatically and are typically used with a gearbox and a brake system.

    Custom Engineered Small Gears From Allied Sinterings

    Allied Sinterings is an industry leader in custom-designed small gears! Our products are precisely manufactured to the highest quality standards to ensure that they meet the specific requirements of our customers. We also use advanced technology to continuously improve our products and services and provide everyone with innovative solutions to their needs.

    Contact us for inquiries, or request a quote to begin your next projects with us!

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