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Malleable and ductile cast irons are used extensively in automotive applications such as clutches, gears, carriers, shafts, bearings, cam, racers, hubs, etc. Recently developed P/M materials can be processed cost efficiently to replace malleable and ductile iron castings. An UTS in excess of 1240 MPa and a YS in excess of 825 MPa can be achieved with one of these new materials. These tensile properties can be coupled with elongations over 2% and impact energies over 25 Joules. This presentation will cover processing routes for these new materials and will identify parts that may benefit from this new technological advancement.

Machinability of powder metal components (P/M) requires a better understanding material compositon, microstructure, and machining process conditions. By employing the appropriate machinability additives and base powder design, machining productivity can be optimized. Through proper application planning, the material supplier, P/M fabricator, and end user can design the P/M system to balance part performance and machinability requirements.