Advantages of Using Powdered Metal….

• A low cost mass production method of manufacturing high quality, strong complex parts.
• Maintain close dimensional tolerances, achieve “net” shaping.
• Provides a good surface finish.
• Eliminates or minimizes machining or assembly operations.
• Availability of a wide variety of alloyed materials.
• Provides materials which may be heat treated for increased strength or wear resistance.
• Reduce scrap losses
• Provides controlled porosity for self lubrication.
• Facilitates manufacturing of complex or unique shapes which would be impractical or impossible with other metal forming processes

Powdered Metal History
The use of metal powders is a technique that dates back to prehistoric times.  Excavations from the ancient Inca and Egyptian sites have uncovered ornaments and implements produced by this process.

Powder metallurgy methods progressed slowly through the years as the process was too slow and to expensive to have broad market applications.  The first modern use for powder metallurgy parts came in the 1920’s with the development of the self-lubricating  bearings and bronze bearings used in automobiles.  With the growth of the automobile industry and more demand, better powders and processes were developed to make better parts at much reduced costs.

By the 1960’s, powdered metallurgy processing became more of a proven technique with engineers designing components and assemblies specifically for powder metal, rather than merely using powder metal to replace wrought parts.  Improved powder properties allowed for greater design possibilities.

A wider acceptance of powder metallurgy is apparent in the types of products using powder metallurgy parts.  By the 1970’s along with the automotive, which has continued to be the greatest utilization, powder metallurgy parts were being used in appliances, farm and garden equipments, hardware, tools, cameras, business machines, sporting goods and military products.

The1980’s have seen growth of powder metallurgy products being used for aircraft turbine engines, as well as growth in both the type and number of parts being used in traditional products like automotive. 

The local powder metallurgy industry has its roots in the carbon factories which were located in the St. Marys area.  These companies, established in the late 1800’s pressed carbon to produce pure carbon parts for the then emerging electric industry.

After World War II, as employees of the carbon companies became aware of the growing powder metallurgy markets, they realized that their know-how could be transferred to the powder metallurgy business.  As employees of these companies gained experience, they would start a company of their own.  Today, approximately 40% of all powder metallurgy manufacturing companies are located in the north central region of Pennsylvania.  The region has aptly become known as the “Powder Metallurgy Capital of the World”.

The Powdered Metal Process
The powder metal process is an economical, environmentally clean, high production method for making parts exactly to or close to final dimensions with little or no machining operations required.  With powder metal it is possible to size, coin or repress parts to close tolerance.  Due to their porosity, they may be impregnated with oil or plastic.
Powder metal parts are created through powder metallurgy (P/M). During this manufacturing process, solid ferrous and nonferrous metal parts are created from metal powder. Metals are first reduced to individual particles through methods including atomization, chemical precipitation, comminution and hydrogen reduction. The resulting powders are impregnated with lubricant. Then, they are compacted in a die cavity at ambient temperature, after which they are in a near net state, or “green state.” Finally, the green parts are sintered in a furnace at temperatures below the melting point of the metal to bond the particles without changing the shape of the part.