Category Archive: Sintered Powdered Metal

How To Find the Right Sintered Metal Parts

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.

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.

What Is Sintered Powdered Metal?

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.

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!