The powder metallurgy process (PM) is a cost effective means to produce a variety of metal products. However, tooling costs and geometric constraints severely restrict part geometry and economic production quantities. A novel powder processing technology is proposed by which fully three dimensional parts can be produced economically in small quantities. The process, based on the machining of compacts prior to sintering, combines the material utilization and production rates of powder metallurgy with the flexibility of machining. The flexibility of the process can be further exploited by integrating it with CAD/CAM facilities and with production equipment to provide a capability for automated production of classes of fully 3-D products. The effects of material formulation, binder selection, machining parameters, binder extraction, and sintering conditions on final part characteristics will be investigated. Critical issues include "green" compact niachinability, final product strength and toughness and the accuracy with which final part dimensions can be predicted. The concepts related to an integrated CAD/CAM powder processing system will also be developed. The anticipated result of this research is the development of a new powder processing technology compatible with the philosophy of flexible manufacturing systems and small batch production.The potential commercial application as described by the awardee: A commercially viable production process is expected to result from the proposed research. The process will reduce material costs and secondary machining costs and furthermore will expand the classes of parts for which PM is a practical process. An integrated CAD/CAM powder processing system will ultimately reduce lead times and inventory costs and will make PM a viable process for complex parts and small production quantities. Allegheny Powder Metallurgy, Inc., is a manufacturing firm specializing in the fabrication of metal parts such as bearings, bushings, structurals, sprockets, and gears.
