Powder Metal Parts and Materials
Powder Metal Parts and Materials
- How are Powder Metal Sintered Parts Made?
- PM Increases Control Over Material Properties and Performance
- Materials Commonly Used in Powder Metal Manufacturing
- What Types of Parts Can Be Made with Powder Metallurgy?
- The Advantages of Powdered Metal Parts
- Industries We Serve
- Why Choose Compax, Inc. for Sintered Powder Metal Parts?
Many different industries require high-volume production of small, precision parts. From gears to levers, and from motor components to cams and beyond, manufacturers look for ways to make these parts affordably without sacrificing quality.
Manufacturing options may include stamping, drawing, blanking, CNC machining, and casting. Depending on the part, material, and features, some of these methods can be high cost.
Powder metal (PM) manufacturing is an alternative that solves many manufacturing challenges, producing high-quality parts with intricate features, high levels of repeatability and precision, and reducing manufacturing costs. Compax, Inc. has over 60 years of experience in powder metallurgy and works with customers in many different industries, including the medical, aerospace, automotive, electronics, security, and other industries.
Learn more about this manufacturing process, how powdered metal blends can improve material properties, and some examples of the applications and advantages of this method.
How are Powder Metal Sintered Parts Made?
Powder metal parts are made from compacted metal powder, then heated in a sintering furnace. The multi-step process includes:
- Metal powders are blended with binders, lubricants, and additives based on application specifications
- Raw material is automatically fed into a die and compacted using press equipment
- This “green compact” is removed from the die and transferred to a sintering furnace.
- During sintering, parts are heated below their melting point in a controlled atmosphere, which creates metallurgical bonds between the particles. The furnace also maintains a precise temperature, time and atmosphere flow rate to minimize variation.
- Parts can be further processed if required (machined, deburred, coated, etc)
PM Increases Control Over Material Properties and Performance
Powder metal manufacturing is an excellent way to fine-tune material properties for specific applications. Formulations can be customized from different metals and alloys in different proportions in order to enhance a range of properties that affect part performance and service life. Examples of properties commonly adjusted include, but are not limited to:
- Corrosion resistance.
- Wear resistance.
- Friction reduction.
- Surface finish.
- Magnetism.
- Porosity.
The sintering process also improves properties like strength and hardness while distributing materials evenly throughout the part. The carefully controlled atmosphere in the furnace also reduces surface oxidation.
Materials Commonly Used in Powder Metal Manufacturing
Compax, Inc. uses top-quality metal powders, lubricants, and alloys that meet the requirements of the Metal Power Industries Federation (MPIF) Standard 35. This standard defines PM specifications and testing guidelines.
Common materials used in PM manufacturing include:
What Types of Parts Can Be Made with Powder Metallurgy?
At Compax, Inc. we work with customers in a wide variety of industries to make mow, medium and high volume quantities of parts. These include multi level complex designs with multiple part features and two and three piece constructions. Some of the types of parts we make include:
Brackets
Bushings
Couplings
Electrical contacts
Levers
Pawls
Pistons
Pulley components
Valve and spring seats
The Advantages of Powdered Metal Parts
Powder metal manufacturing provides several advantages for engineers and designers in need of an efficient and cost-effective way to manufacture reliable metal components. These include:
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Precision
Precision
Compax, Inc. designs all tooling in-house specific for your part. . Custom dies ensure parts are the exact shape and size required, and they make the process highly repeatable. -
Low waste
Low waste
Powder metal manufacturing is a near-net-shape method, with material use rates often beyond 99%.
-
Less finishing
Less finishing
Sintered parts are usually made to their final shape, which reduces the amount of grinding, machining, or finishing after processing is complete. -
Customization
Customization
Material blends are optimized to achieve specified properties and characteristics in the finished part, including things like strength, conductivity, wear resistance, or hardness. -
Versatile for complex parts
Versatile for complex parts
Compax can reproduce fine details and intricate part features reliably and accurately, especially for parts that would be difficult or impossible to fabricate or machine in other ways.
Industries We Serve
Compax, Inc. serves customers in many industries that need metal parts and components with specialized material properties, intricate features, and high volumes. Over the years we have partnered with companies in the following industries:
Aerospace
Automotive
Gerotors
Motorcycles
Hand and power tools
Electronics and telecommunications
Outdoor power equipment
Locks and security
Medical and dental equipment
Pumps
Vacuums
Valve assemblies
Musical instruments
Shock absorbers
Oil services industry
Wind turbine equipment
Why Choose Compax, Inc. for Sintered Powder Metal Parts?
As an experienced powder metallurgy manufacturer, we understand that each application and industry has unique requirements. We work closely with each customer to meet their requirements and goals.
Compax, Inc. maintains state-of-the-art production facilities equipped with compaction with presses ranging from 2 to 250 tons, belt, pusher and batch sintering furnaces, and automated CMMs, image measurement systems, testing and inspection systems.
We also offer a range of secondary and finishing services that include CNC machining, coining, grinding, deburring, oil and resin impregnation, PTFE coating diamond honing, and burnishing.
Contact Compax, Inc. to Learn More About Our Powdered Metal Manufacturing Capabilities
Since 1962, Compax, Inc. has been producing high-quality powdered metal parts that are both durable and reliable. We are ISO 9001:2015 certified and committed to quality in all aspects of our work.
Contact us to learn more about powder metal manufacturing and the advantages it holds for your applications. You can also request a quote online for your next project.