In the alternative fabrication process considered—a machined and ground stamping, assembled via welding with a pin—the journals represented a substantial cost. Careful engineering analysis by the PM fabricator determined that only a portion of the journal radius was required for proper functioning, and this could be achieved via a face-form on the punch face. The sintering temperature, ramp-up, and cool-down process had to be precisely controlled in order to prevent the component from warping out of tolerance.
The part fabricator overcame a challenging PM component to create a complex, 3D shape in a high-performance material for a fraction of the cost of a heat-treated, machined, and welded stamping component. Using PM saved the end user approximately 40% when compared to the alternative process.