Selecting the right process to produce a component can be a daunting task; requiring balancing design, tolerancing, and cost-effectiveness. Technologies like casting, milling, and grinding have been around for centuries, and although industries are familiar with these conventional processes, more sustainable competing processes like powder metallurgy offer benefits that may simply be too good to ignore. Precision, accuracy, flexibility, and cost-effectiveness are just a few of the advantages associated with powder metal applications.
The Powder Metallurgy Process
Beginning early in the design process MPP works with customers to create an efficient and cost-effective part design and select the right material. MPP is experienced in utilizing a wide range of ferrous and non-ferrous materials, including iron, stainless steel, copper, aluminum, and soft magnetic materials. When the application calls for a custom alloy, MPPs metallurgical experts can design and simulate new metal alloys to meet customer requirements. All PM processes start with compaction, tooling is custom designed and built to fit the compaction press required for the component. A range of press tonnages are available to service both large and small components. Metal powder is then compressed, using several tons of force, to shape the powder to the part specifications. Once compacted, parts are moved to furnaces with strict temperature and atmosphere control to begin the sintering process. Sintering creates the molecular bonds between metal partials that ultimately create the structure of the part. After the part is sintered a variety of secondary operations can be used to achieve further tolerances. Utilizing the resources and process MPP has to offer can lead to significant cost reductions for the end user.
Cost Effectiveness / Waste Reduction
As an innovative technology, metal forming via powder metallurgy is more cost-effective than other technologies because of the reduction in waste, reduced need for secondary machining, and production speed. In fact, it’s easier for engineers to combine parts and create more complex solutions, eliminating the necessity for assembly and reducing the supply chain; creating dramatic cost savings for manufacturers. The powder metallurgy process creates significantly less scrap, providing just another form of cost savings. If your company is looking to improve its sustainability and stabilize your supply chain, this certified green technology is ideal for your components.
Flexibility, Precision, and Accuracy
Powder metallurgy also allows components to be made from unique alloys with tailored properties to match specific tolerances or performance requirements, such as operating wear resistance, corrosive environments, and high temperatures,
Unlike other metal-forming processes, powdered metal manufacturing eliminates many additional processes resulting in lower final cost. The powder metallurgy process allows for creation of uniform, consistent parts, while the process uses less energy, and creates little material waste. By manufacturing to a near-net shape design metal waste is reduced while also reducing post-production processes. PM utilizes upwards of 97% of input material and is classified as a green technology in metal manufacturing.
If your business relies on metal-forming parts or products, you should explore powder metallurgy in depth to determine if it’s the right technology for your needs.
Interested In Learning More?
Metal Powder Products, LLC (MPP), an expert in powder metallurgy, can combine the right mix of metal powders to meet your unique strength and performance requirements to develop customized, complex, and sustainable components that enhance your products. With more than a half a century of experience, MPP is a pioneer in volume production of aluminum products, and an industry leader in the manufacturing of steel, iron, and stainless steel materials.
Need assistance with your parts manufacturing or want to learn more about powdered metal components?