Capstan: Brushless DC Actuator Gear
Capstan California earned a Grand Prize in the Automotive/Engine Category for Conventional PM components for its compact brushless dc actuator gear designed to improve engine performance and reduce nitrogen oxide emissions for on- and off-road commercial diesel-engine vehicles. Made from SS-316L, all gear dimensions meet AGMA level 7 requirements. This stainless-steel precision gear required carbide tooling for compaction.
Indo-MIM Pvt. Ltd.: Turbo Charger Vane
Indo-MIM Pvt Ltd earned a Grand Prize in the Automotive/Engine Category for MIM Components for a turbo charger vane. The part complexity includes a thin-walled, curved profile with a thick lug on top. A two-drop, hot runner tool makes 12 parts per shot without any slide involvement.
Stackpole International: Clutch Backing Plate and Pressure-Apply Piston
Stackpole International earned a Grand Prize in the Automotive/Transmission Category for Conventional PM components for a clutch backing plate and pressure-apply piston used in the General Motors 9T50/65 Hydra-Matic transmission. The parts form a combined sub-assembly within the transmission that includes a central hub and two roller-bearing races. Compacting the parts involved multiple-element tooling. It also called for a complex die design to form the near-net-shape geometry.
Indo-MIM Pvt. Ltd.: Latching Plate and Collapsible Roof Assembly
In the Automotive/Chassis Category for MIM components, a grand prize was awarded to Indo-MIM Pvt. Ltd., India, for its MIM-17-4 PH latching plate used in a collapsible roof assembly for passenger cars. A solid-film lubricant coating applied to the part reduces friction during operation of the collapsible roof. Molding was a challenge as the part has two thin features joined by a thicker slotted section.
ASCO Sintering Co.: Miniature Planetary Gearset
ASCO Sintering Co. earned a grand prize in the Lawn & Garden/Off Highway Category for Conventional PM components for its miniature planetary gear carrier set used in a commercial rotary irrigation system. The parts are made from SS-316N1,N2 and compacted to a green density of 6.6 g/cm3.
Indo-MIM Pvt. Ltd.: Ski Boot Bindings
A Grand Prize in the Hand Tools/Recreation Category for MIM components was earned by Indo-MIM Pvt. Ltd., for right- and left-hand bindings in ski shoes. The parts are made from MIM-4605 that is zinc-blue passivated for corrosion resistance. Previously the parts were cast and required many secondary operations to meet the desired configuration and dimensional tolerances.
ASCO Sintering: Spring Seat
ASCO Sintering earned a grand prize In the Industrial Motors/Controls & Hydraulics Category for Conventional PM components for its spring seat for a hydraulic valve actuator. The part is made from SS-316H-20 and is compacted to a green density of 6.5 g/cm3 prior to sintering. The five blades of the component are too long and thin to be compacted to net shape directly, so extra material is added in the region of the blades. A low-cost turning operation gives the part its final geometry.
Indo-MIM Pvt. Ltd.: Keeper and Ramp for a Hinge
A Grand Prize was awarded to Indo-MIM Pvt. Ltd., India, in the Hardware/Appliances Category for MIM components for two MIM-17-4 PH parts, a keeper and a ramp used in a door-hinge assembly. The keeper has a thick but slotted, curved profile that extends about 3 in. By using three slides—two to form the hole running along the length, and another to form the slot at the center—two parts are produced per shot. Previously, the parts were cast and required considerable machining to achieve the desired dimensions.
Indo-MIM Pvt. Ltd.: Camera Mount
In the Medical/Dental Category for MIM components, Indo-MIM Pvt Ltd earned a grand prize for its MIM-17-4 PH K-mount part used in a digital surgical camera. The challenge in molding was to develop a slide mechanism strong enough to form the y-section with ease and with precise matching to avoid flash. Previously, the part was made as two separate pieces that were subsequently welded. This tended to create sharp edges that damaged the cable during use.
Catalus Corp.: Hole Cover
In the Automotive/Engine Category for Conventional PM Components, an Award of Distinctions was earned by Catalus Corp for an access-hole cover used to transfer collected oil from the crankcase ventilation subsystem at the top of the engine into the engine block. It had to use an existing bolt pattern and have a low profile to permit clearance to the nearby engine control module. The PM part replaced an assembly of multiple stamped, machined, and drawn components and resulted in a 27% weight saving.
Nichols Portland LLS: Rotor Vane
An Award of Distinction in the Automotive/Engine Category for Conventional PM Components was earned by Nichols Portland LLC for a rotor vane used in an engine lubrication oil-pump system. The part is sized, face ground, deburred, and cleaned. The product application requires high accuracy of rotor radial dimensions, ID spline, and vane-slot features to reduce internal pump leaks and achieve the required mechanical efficiency.
Indo-MIM Pvt. Ltd.: Valve Poppet
Indo-MIM Pvt. Ltd earned an Award of Distinction in the Automotive/Engine Category for MIM Components for its valve poppet used in the fuel injection of a diesel engine for heavy trucks. The extremely small part has a tight tolerance on its outside diameter and the perpendicularity of the three legs. Part-specific forms were used during sintering to maintain part quality.
Ford Motor Co.: Control Bracket
In the Automotive/Transmission Category for Conventional PM Components, Ford and GKN Powder Metallurgy earned an Award of Distinction for their transmission park-range-sensor control bracket that acts as a stop to prevent over travel of a transmission rod in the parking subsystem. Although mechanical properties are not a major concern, the positional tolerance of the part once bolted in place is critical.
FMS Corp.: Fan Clutch Parts
FMS Corp. earned an Award of Distinction was in the Automotive/Chassis Category for Conventional PM Components for its fan clutch components made for cooling subsystems for semi-tractors and other large, diesel-engine vehicles. The six PM parts include a bushing-tensioner retainer and an index coupler. All six parts are made from FC-0208-50. The PM parts replace machined components and offer a 60% cost saving.
FMS Corp.: Camshaft and Water-Pump Sprocket
An Award of Distinction was earned by FMS Corp. in the Hand Tools/Recreation Conventional PM Components Category for its camshaft and water-pump sprockets used in the Polaris Slingshot, three-wheel, side-by-side “moto roadster.” The water-pump sprocket was especially challenging, as the customer wanted a one-piece shaft/sprocket design. The PM components represent a 40% cost saving compared with machining.
Webster-Hoff Corp.: Racheting Lock
In the Hardware/Appliances Category for Conventional PM components, Webster-Hoff Corp. earned an Award of Distinction for its ratcheting lock which was part of the locking mechanism in an adjustable office chair arm. Special fixturing is needed during sintering so that the part will meet the tolerances required for post-sintering, drilling, and tapping.