GKN Sinter Metals of Auburn Hills, MI won a grand prize in an annual powder
metal design competition for a carrier and one-way rocker clutch assembly made
for Ford Motor.
Designed for powder metal (PM), the assembly uses fewer components
compared to alternate designs and manufacturing methods, reducing the mass of
the assembly, improving fuel efficiency without sacrificing performance.
Used in the new Ford Super Duty TorqShift six-speed automatic
transmission, the hybrid assembly contains five powder steel parts weighing a
total of 17 lb. The sinter-brazed subassembly consists of four multi-level PM
parts, of which three parts (cage, spider, and carrier plate) are made to a
density of 6.8 g/cm3
The rocker plate is sinter-hardened during the sinter- brazing phase
and has a density of 7.0 g/cm3
. The assembly also has a
doubled-pressed and double-sintered cam plate made to 7.3 g/cm3
density with an ultimate tensile strength of 170,000 psi and a mean tempered
hardness exceeding 40 HRC.
To form the parts and maintain precision tolerances, special tooling
was developed and used with unconventional press motions. Ford subjected the
assembly to ultimate torsional torque loading at a minimum of 8,000 ft-lb and
fatigue testing at a minimum of 299,000 cycles at 1,730 ft-lb.
"The application provided an estimated 20 percent cost savings over competitive
processes," according to a statement from the MPIF.
GKN Sinter Metals won another grand prize in the automotive chassis category
for a differential bearing adjuster made for American Axle & Manufacturing
and used in the GMT 900 rear differential on GM Tahoe and Yukon models.
Other winners are:
A porous bronze filter made by Capstan California, Carson, CA. for
Chase Filters and Components received the grand prize in the aerospace/military
Parmatech Corp., Petaluma, CA, earned the grand prize in the hand
tools/recreation category for a 420 stainless-steel, metal injection molded (MIM)
hunting arrowhead made for Optek Precision Tooling Ltd.
- A PMcopper-steel outer hub
exit spindle used in electronic door locks won the grand prize in the
hardware/appliances category. Made by ASCO Sintering Co., Commerce, CA, for
Ingersoll Rand Security Technologies (Schlage), the part connects a standard
lock and an exit device.
Awards of Distinction
- FloMet of Deland, FL earned the grand prize in the medical/dental
category for a housing cup and lid used in an audio device with magnetic
Cloyes Gear & Products Inc., Paris, AR - intake sprocket gear and
an exhaust gear used in a coupling assembly.
- Megamet Solid Metals Inc., Earth City, MO - a rear sight used on
sporting and military rifles.
- Indo-US MIM Tec (P) Ltd., Bangalore, India - a 17-4PH stainless steel
- Webster-Hoff Corp., Glendale Heights, IL - a PM sinter-hardened steel
cam and bushing used in a manual paper hole punching machine.
- Lovejoy Sintered Solutions, Downers Grove, IL - a PM diffusion-alloyed
- Burgess-Norton Mfg. Co., Geneva, I- a PM steel crimp retainer operating
in a valve assembly.
- Kinetics Climax, Wilsonville, OR - a 17-PH stainless steel distal
channel retainer formed via the MIM process.
- Capstan California - a bronze filter plate.