CA3050801A1 - Process for producing sintered article - Google Patents

Process for producing sintered article Download PDF

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Publication number
CA3050801A1
CA3050801A1 CA3050801A CA3050801A CA3050801A1 CA 3050801 A1 CA3050801 A1 CA 3050801A1 CA 3050801 A CA3050801 A CA 3050801A CA 3050801 A CA3050801 A CA 3050801A CA 3050801 A1 CA3050801 A1 CA 3050801A1
Authority
CA
Canada
Prior art keywords
compact
protruding post
plate
protruding
post
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA3050801A
Other languages
French (fr)
Inventor
N. Semih Demir
Jan Mis
Joseph Timmermans
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson Electric International AG
Original Assignee
Johnson Electric International AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Electric International AG filed Critical Johnson Electric International AG
Priority to CA3050801A priority Critical patent/CA3050801A1/en
Publication of CA3050801A1 publication Critical patent/CA3050801A1/en
Abandoned legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/08Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B22F7/064Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using an intermediate powder layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/005Article surface comprising protrusions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/02Making ferrous alloys by powder metallurgy

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Powder Metallurgy (AREA)

Abstract

A process of producing a sintered powder metal article includes: blending powders of a selected composition; pressing the blended powders to form a first compact comprising a first protruding post and a second compact comprising a second post; and sintering the first compact and the second compact and joining the first protruding post and the second protruding post by sinter-brazing to form the sintered powder metal article.

Description

TITLE
PROCESS FOR PRODUCING SINTERED ARTICLE
FIELD
100011 The present disclosure relates to sintered articles, and particularly to a planetary carrier assembly comprising two components that are connected to each other by sinter-brazing and a design that considerably increases the strength of the assembly compared to the prior art for making the sintered article.
BACKGROUND
100021 Powder metallurgy (PM) is an important process used in the manufacture of automotive, marine and aviation components. For example, conventional press and sinter process has been widely used for manufacturing components such as planetary gear carriers. A typical planetary carrier usually includes a plate, a spider and a number of legs connecting the plate to the spider. For some planetary carries, the legs are connected to plate by sinter-brazing. Sharp corners are formed at positions where the legs and the plate are joined. One problem with such manufacturing process is that higher stress concentration exists at the sharp corners.
BRIEF DESCRIPTION OF THE DRAWINGS
100031 Fig. 1 is an isometric view of a planetary gear carrier compact including a first compact and a second compact.
100041 Fig. 2 is an isometric view of the first compact of Fig. 1.
100051 Fig. 3 is an isometric view of the second compact of Fig. 1.
100061 Fig. 4 is a flow chart of a process for making a sintered article according to one embodiment.
100071 Fig. 5 is a flow chart of a process for making a sintered article according one embodiment.
100081 Fig. 6 illustrates the isometric view of prior art for the first compact.
100091 Fig. 7 illustrates the isometric view of prior art for the second compact.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
100101 Embodiments of the present disclosure will be described in detail in conjunction with the drawings. It should be noted that the figures are illustrative rather than limiting.
The figures are not drawn to scale, do not illustrate every aspect of the described embodiments, and do not limit the scope of the present disclosure.
[0011] A sintered article according to an embodiment of the present disclosure includes a first component, a second component and one or more connecting members connecting the first component to the second component. The following descriptions provide an example of the sinter article taken in the form of a planetary gear carrier.
It should be noted that the sintered article is not limited to the planetary gear carrier described below.
[0012] Referring to FIGS. 1-3, the planetary gear carrier includes a first component and a second component that are respectively made by sintering a first compact 10 and a second compact 20. The first compact 10 and the second compact 20 are each formed by applying pressure to powders of a selected composition.
[0013] The first compact 10 includes a first plate 11 that can be circular, triangular, square or any other shape depending on application and a number of first protruding posts 12. The protruding posts 12 protrude from one side of the plate 11, and are distributed around a hole defined in the center of the plate 11. Each protruding post 12 has a cross section that is typically of similar isosceles trapezoids, but can also be cylindrical or any other shape depending on requirements. Here, the cross section is taken parallel to the side where the protruding posts 12 protrude. Each protruding post 12 has a height substantially sufficient to incorporate corner radii, and also when stacked with second protruding posts of the second compact 20 total height is suitable for the required distance between the first plate 11 and the second plate of the second compact 20. The protruding posts 12 are sized in such a way that they can provide a stable support for second protruding posts of the second compact 20 to stack thereon. The second plate and the second protruding posts will be described in detail in the following descriptions.
100141 The second compact 20 includes a second plate 21 that can be circular, triangular, square or any other shape depending on application and a number of second protruding posts 22. The second protruding posts 22 protrude from one side of the second
2 plate 21, and are evenly distributed around a hole defined in the center of the second plate 21. Each second protruding post 22 has a cross section substantially the same as the cross section of a corresponding first protruding post 12. Here, the cross section of the second protruding post is taken parallel to the side where the protruding posts 22 protrude.
100151 In the embodiment, the first protruding posts 12 are substantially perpendicular to the plate 11, and the second protruding posts 22 are substantially perpendicular to the second circular plate 21. Corner radii 13 are formed between the first protruding posts 12 and the first plate 11, and corner radii 23 are also formed between the second protruding posts 22 and the second plate 21.
100161 In the embodiment, the first compact 10 and the second compact 20 are configured in such a way that a gap 3 is formed between the first protruding posts 12 and the second protruding posts 22 so as to place brazing material therein when the first compact 10 is placed on the second compact 20.
[0017] In one embodiment, each first protruding post 12 includes a positioning protrusion 121 and each second protruding post 22 defines a positioning recess 221 that allows a corresponding positioning protrusion 121 to fit therein so as to position the first compact 10. Specifically, the positioning protrusion 121 is formed on the end surface of the first protruding post 12, and the positioning recess 221 is defined in the end surface of the second protruding post 22. The gap 3 is formed between the top end surfaces of the first protruding posts 12 and the second end surfaces of the second protruding posts 22 when the first positioning protrusions 121 fit in the corresponding positioning recesses 221. After the first compact 10 is placed on the second compact 20 with the brazing material also placed between the first protruding posts 12 and the second protruding posts 22, the first compact 10 and the second compact 20 with the brazing material are assembled as shown in Fig 1. Then assemblies are brought into a sintering furnace, so that both compacts 10 and 20 are sintered at a predetermined temperature, at the same time that the brazing material is fused so as to join the first protruding posts 12 and the second protruding posts 22.
10018] In the embodiment, the brazed joints for joining the first compact 10 and the second compact 20 are located between the ends of the first protruding posts 12 and the
3 second protruding posts 22. Compared with conventional brazed joints that are formed between the plate and the legs, no sharp corners are formed between the protruding posts 12/22 and the circular plates 11/21. In addition, the first protruding posts 12 and the second protruding posts 22 have substantially the same sized cross section. No sharp corners are formed at the positions where the first protruding posts 12 and the second protruding posts 22 are joined.
100191 Compared to conventional planetary gear carriers, and the prior art described and that uses components 1 and 2 as shown in Figures 6 and 7, the planetary gear carrier produced by using the processes of the above embodiments eliminates the sharp corners between the plate and the legs, and is thus capable of withstanding higher torque. Further, sensitivity to brazing flaws or imperfections is reduced by moving the joint away from the highest stress location.
[0020] Referring to FIG. 4, in one embodiment, a process for making the sintered article includes the following steps: Step S401: blending powders of a selected composition; Step S402: pressing the blended powders to form the first compact 10 having a first protruding post 12 and a second compact 20 having a second post 22;
and Step S403: sintering the first compact 10 and the second compact 20 and joining the first protruding post 12 and the second protruding post 22 by sinter-brazing to form the sintered powder metal article.
100211 Referring to FIG. 5, in an alternative embodiment, a process for making the sintered article includes the following steps: Step S501: blending powders of a selected composition; Step S502: compacting the blended powders to form the first compact 10 having a first protruding post 12 and a second compact 20 having a second post 22; Step S503: positioning the first compact 10 with respect to the second compact 20, with a brazing material placed between the first protruding post 12 and the second protruding post 22; and Step S504: heating to sinter the first compact 10 and the second compact 20 and fuse the brazing material so as to join the first protruding post 12 and the second protruding post 22 to form the sintered powder metal article.
[0022] In the embodiment, the manufacturing method described herein can be applied to a broad range of alloy compositions as required. Typical powders that can be used with
4 the process described herein to produce the sintered powder metal articles include a number of compositions with the remainder being iron and unavoidable impurities.
100231 The formulated ferrous blend of powder, either admixed alloying powders, pre-alloyed iron, or partially pre-alloyed iron, together with carbon (which is usually added as graphite), ferro alloys if required, and lubricant, will be compacted in the usual manner as described by pressing in rigid tools.
100241 The compacted article is then sintered either at conventional temperatures for prealloyed and partially prealloyed iron which are, for example, in the range of 1100 C to 1350 C. Sintering the base iron powder with ferro alloys is conducted at high temperature sintering generally greater than 1250 C. During the sintering, the brazing material will be fused and join the first protruding posts 12 and the second protruding posts 22.
100251 According to the embodiments of the present disclosure, corner radii is incorporated by designing the first compact 10 with a short post protruding from the plate, which facilitates the reduction of stress concentration where highest resultant force is. In addition, it is conducive to reducing deflection by designing the first compact 10 with a short post because the first component made by sintering the first compact has a thicker cross section.
100261 According to the embodiments of the present disclosure, the processes enable incorporation of radii at both ends of the legs, i.e., the part made by sintering the first and the second protruding posts, where highest stresses are seen, thereby improving the strength of the sintered article.
100271 According to the embodiments of the present disclosure, brazed joint can withstand higher forces due to reduction of deflection of the first component.
Samples tested showed 70% improvement as measured in terms of separation force.
100281 The design claim and the art, as shown, is to change the construction of prior art from what is described and shown in Fig. 6 & 7, to Fig. 2 & 3 thus incorporating corner radii for the protrusions of both component 1 and 2. These corners, when the sinter brazed assembly is subjected to operating torque, suffer from the high stresses.
Prior art, once assembled results in radius on component 10 and a sharp corner where it joins component 20 whereas claim of this new design is that by incorporating radii on both components assembly is capable of carrying higher torque since stress is reduced.

Claims (15)

CLAIMS:
1. A process of producing a sintered powder metal article, the process comprising:
blending powders of a selected composition;
pressing the blended powders to form a first compact comprising a first protruding post and a second compact comprising a second post; and sintering the first compact and the second compact and joining the first protruding post and the second protruding post by sinter-brazing to form the sintered powder metal article.
2. The process of claim 1, wherein the first protruding post is formed to have a cross section substantially the same as a cross section of the second protruding post.
3. The process of claim 1, wherein the first protruding post is formed to comprise a positioning protrusion and the second protruding post is formed to define a positioning recess that allows the positioning protrusion to fit therein so as to position the first compact.
4. The process of claim 3, wherein the positioning protrusion is formed on a first end surface of the first protruding post, the positioning recess is defined in a second end surface of the second protruding post, and a gap is formed between the first end surface and the second end surface when the first positioning protrusion fits in the positioning recess.
5. The process of claim 1, wherein the sintering and the joining are carried out simultaneously.
6. The process of claim 1, wherein the first compact comprises a first plate, the second compact comprises a second plate, the first protruding post protrudes from the first plate with first corner radii formed therebetween, and the second protruding post protrudes from the second plate with second corner radii formed therebetween.
7. A process of producing a sintered powder metal carrier, the process comprising:

blending powders of a selected composition;
compacting the blended powders to form a first compact comprising a first protruding post and a second compact comprising a second post;
positioning the first compact with respect to the second compact, with a brazing material disposed between the first protruding post and the second protruding post; and heating to sinter the first compact and the second compact and fuse the brazing material so as to join the first protruding post and the second protruding post to form the sintered powder metal article.
8. The process of claim 7, wherein the first protruding post is formed to have a cross section substantially the same as a cross section of the second protruding post.
9. The process of claim 7, wherein the first protruding post is formed to comprise a positioning protrusion and the second protruding post is formed to define a positioning recess that allows the positioning protrusion to fit therein so as to position the first compact.
10. The process of claim 9, wherein the positioning protrusion is formed on a first end surface of the first protruding post, the positioning recess is defined in a second end surface of the second protruding post, a gap is formed between the first end surface and the second end surface when the first positioning protrusion fits in the positioning recess, and the brazing material is disposed within the gap.
11. The process of claim 7, wherein the first compact comprises a first plate, the second compact comprises a second plate, the first protruding post protrudes from the first plate with first corner radii formed therebetween, and the second protruding post protrudes from the second plate with second corner radii formed therebetween.
12. A sintered article comprising a first component and a second component that are respectively made by sintering a first compact and a second compact, wherein the first compact comprises a first protruding post, and the compact comprises a second protruding post, the first compact and the second compact are configured in such a way that a gap is formed between the first protruding post and the second protruding post so as to place a brazing material therein when the first compact is placed on the second compact.
13. The sintered article of claim 12, wherein the first compact comprises a first plate, the second compact comprises a second plate, the first protruding post protrudes from the first plate with first corner radii formed therebetween, the second protruding post protrudes from the second plate with second corner radii formed therebetween, and the first protruding post has a cross section substantially the same as a cross section of the second protruding post.
14. The sintered article of claim 12, wherein the first protruding post comprises a positioning protrusion and the second protruding post defines a positioning recess that allows the positioning protrusion to fit therein so as to position the first compact.
15. The sintered article of claim 14, wherein the positioning protrusion is formed on a first end surface of the first protruding post, the positioning recess is defined in a second end surface of the second protruding post, the gap is formed between the first end surface and the second end surface when the first positioning protrusion fits in the positioning recess.
CA3050801A 2019-07-30 2019-07-30 Process for producing sintered article Abandoned CA3050801A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA3050801A CA3050801A1 (en) 2019-07-30 2019-07-30 Process for producing sintered article

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA3050801A CA3050801A1 (en) 2019-07-30 2019-07-30 Process for producing sintered article

Publications (1)

Publication Number Publication Date
CA3050801A1 true CA3050801A1 (en) 2021-01-30

Family

ID=74222129

Family Applications (1)

Application Number Title Priority Date Filing Date
CA3050801A Abandoned CA3050801A1 (en) 2019-07-30 2019-07-30 Process for producing sintered article

Country Status (1)

Country Link
CA (1) CA3050801A1 (en)

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Legal Events

Date Code Title Description
FZDE Discontinued

Effective date: 20220408

FZDE Discontinued

Effective date: 20220408