Powder Forging Process - Important Near-Net-Shape Forming Process for Mechanical Parts

As one of the processes with less or no cutting in the manufacture of metal parts, powder metallurgy adopts die pressing and sintering processes, which has the characteristics of saving materials, improving efficiency and reducing costs. However, it is difficult for general powder metallurgy parts to reach a high level in terms of density and mechanical properties.

The powder forging process solves this problem well. Through the organic combination of powder metallurgy and precision forging processes, powder metallurgy materials are isotropic and uniform in material. The density is close to or reaches the level of smelting steel. The comprehensive performance of the material reaches or even exceeds the performance of alloy steel. It has become one of the important near-net-shape forming processes for mechanical parts.

The process advantages of powder forging are:

1. Near-net-shape     From blank pressing to forging, die forming is used, and blanks or final products close to the size of parts can be obtained. It is an advanced manufacturing technology with less or no cutting, and the material utilization rate can be as high as more than 95%. Sintering and forging are carried out under a protective atmosphere, with less surface oxidation, improved forging accuracy, and long die life. 2. High mechanical properties After powder forging and heat treatment, the material density reaches more than 98% of the theoretical density, the internal structure is uniform and segregated, and the mechanical properties reach or even exceed those of ordinary die forging steel. In particular, the fatigue strength is significantly improved compared to ordinary alloy steel, and it is widely used in parts with high fatigue resistance requirements such as automobile connecting rods.
3. Adjustable composition    Using powder as raw material, the material composition can be adjusted on a large scale according to the actual use conditions and performance requirements of the parts to obtain the maximum cost performance.
4. High production efficiency    Due to the use of precision molds from blank manufacturing to forging, there are fewer processes and shorter processes, which can meet large-scale and automated production and have higher production efficiency.
5. Low product cost    Due to the high material utilization rate and processing accuracy, rough processing is omitted, the intermediate processes are reduced, and less cutting is achieved, and the product cost is greatly reduced. In particular, mechanical parts with complex shapes, many processing steps, and more processing hours can effectively reduce costs by using powder forging.

The powder forging process can give full play to the advantages of mold forming, and has the characteristics of saving materials, improving efficiency, and reducing costs. Through the organic combination of powder metallurgy and precision forging technology, the comprehensive performance of parts reaches or even exceeds the performance of alloy steel. Auto parts that can be forged by powder include: engine parts; transmission parts; chassis parts; automatic transmission parts. Compared with traditional processes, parts with more complex shapes, fewer steps, and larger processing volumes are more suitable for powder forging, such as connecting rods, gears, etc.

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