Powder Metallurgy Gear

Powder metallurgy technology, as an advanced material preparation and forming process, has the following significant advantages:
High material utilization rate
Powder metallurgy adopts near net forming technology, with material loss of only 1% -5%, far lower than the 80% loss rate of traditional mechanical processing. By directly pressing and forming, subsequent cutting processing can be reduced, achieving a material utilization rate of over 90%.
Low manufacturing cost for complex structures
This process can directly manufacture complex structural parts such as perforated gears and interlayers, avoiding multiple processes. For example, components such as car synchronous pulleys and valve guides can be molded in one go, significantly reducing processing difficulty and costs.
Ability to prepare special materials
Can process materials that are difficult to prepare using traditional techniques, such as refractory metals (such as tungsten), pseudo alloys, porous materials, etc. For example, manufacturing special functional materials such as tungsten filament or copper tungsten alloy for light bulbs.
Accurate control of ingredients
Powder metallurgy does not melt materials during the material production process, avoiding component segregation and enabling precise control of material ratio and uniformity. Sintering is carried out in a vacuum or reducing atmosphere, resulting in higher purity of the product.
Advantages of mass production
Suitable for the production of products with a large number of uniform shapes (such as gears), it can greatly improve efficiency and reduce manufacturing costs. The product consistency is good, and the possibility of scrapping is relatively small.
environmental protection and energy conservation
Less processes and low energy consumption, in line with the concept of green manufacturing. Through techniques such as pore oil immersion, self-lubricating function can also be achieved, improving the wear resistance of parts.

The process is 

prepare the powder, mix them, press the metal powder with high pressure machine, and then sinter them to get hard solid parts. 

Since it is formed by powder, the sizes are very precise. Accordingly, we don't need CNC machine these gear’s teeth and the out shape,

Then can reduce the machining process, and save the cost, in comparison with CNC machining from the bar or forging and casting.

Now there are many powder metallurgy parts used in auto parts, audio device, medical machinery, aerospace industry, and power tools.

Sometimes the process might be cheaper and easier for some parts made by casting or forging and by CNC machining,but need high quantity

 while we can think about using this process if some parts are hard to be machined.

such as some gear teeth, curve surface,and special feature,