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Connecting rods manufactured by the Precision Powder Forged (P/F) process offer several distinct advantages over those produced by all other methods including the state-of-the-art forged steel process. Precision P/F connecting rods have mechanical properties equivalent to those made from forged steel, with the added benefits of greater design flexibility, superior dimensional and weight precision, simplified finish machining and assembly, better machinability, and increased consistency because of highly stable metallurgy and a robust and reliable manufacturing process. The inherent flexibility of the P/F process also facilitates tailoring materials to achieve the optimal balance of strength and machinability for a given application. In combination, these advantages result in a product that requires less capital investment for finish machining, is more environmentally conscious by generating substantially less waste, exhibits better total performance, and has lower total cost.

Transverse gear rolling has the potential to deliver both increased dimensional precision and performance in combination with the established processing methods for P/M gear manufacturing. In order to effectively design the rolling process, a constitutive understanding of both the kinematical boundary conditions and the densification behavior of different P/M materials is necessary. The successful application of a comprehensive process design strategy is illustrated along with highlights of several example products.