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Development of new PM materials and processes during the last decade has led to an increased use of PM components in automotive applications. To maintain its competitiveness towards other manufacturing techniques, the PM industry must continue to combine high demands on mechanical properties with maintained or even improved close tolerances of the sintered components in a robust, reliable and cost effective way. As the PM technology offers a wide selection of alloys that can be processed under a variety of conditions it is of outmost importance to know the influence of each on the both performance and robustness of the PM part to secure a reliable function in the final application. In this paper the influence of material and processing conditions on dimensional tolerances and reliability are discussed. A case study is presented describing results from manufacturing of belt pulleys in a state-of-the-art hydraulic press.

This paper presents the progress in Powder Metallurgy (PM) Gears, including examples of how to combine the disciplines of materials-, design- and process technology to push the limits towards increased performance, reduced weight, energy consumption and total manufacturing cost. Advancements in materials and manufacturing technology for PM gears will be presented as well as the result from simulations and reverse engineering work on existing automotive transmissions. The results from this work show that the amount and type of load on the individual gears in auto transmissions are very different and this gives room for optimized selection of material and manufacturing process.