Powder Metallurgy

FORGING PROCESS OF CONNECTING ROD

Group 1 :
Dera Lesmana
Netron Silalahi
Chandra Simanjuntak
Trie Djoko. S.
Topan Nugraha
Natur Paku Birowo
Nazario Monteiro

Introduction
Powder metallurgy (P/M) is one of several net or near net shape
processes for the manufacture of structural metal parts. Due to low
cost in material and time saving in the consolidation and sintering
processes, more and more P/M parts are being used on cars and
motorcycles. But P/M has an obvious disadvantage. It is difficult to
achieve alloy steel level on density and mechanical properties.
Although some processes, such as complex pressing, injection
molding, selecting prealloy powder and warm pressing, can be used
to try to obtain a fully densified part, the density can not reach 96% of
theoretical density. On the other hand, the above processes also
increase the cost significantly.

Elemental
or alloy
metal
powders
Additive
(Die
lubricants
or
graphite)
Mixing
Hot compaction
Isostatic,
Extrusion Die
compacting
Spraying,
Sintering
Pressureless
Cold compaction
Die compacting,
Isostatic, Rolling,
Injection molding,
Slip casting
Sintering
Vacuum or
Atmospheric
Optional
manufacturing step
Sizing, Repressing,
Resintering,
Forging, Coining,
Metal infiltration,
Oil Impregnation
Optional finishing
steps
Heat treating,
Tumbling, Plating,
Machining, Stream
treating
Finish
product
P/M Process
PRODUCT
P/M PROCESS
Composition Design
Several aspects for composition design :
1. Matrix material being carbon steel.
2. Powder porosity being easy to eliminate.
3. Hardenability and the basic hardness more than HRc30 after
hardening.
4. The need of a wear-resisting carburization layer.
5. High powder quality and properties.

Mixing
Popular lubricants are stearic
acid, stearin, metallic
stearates, especially zinc
stearate, and increasingly,
other organic compounds of a
waxynature.

Compacting
Synchronous compacting method Density distribution of the rod compact
Density Compact Formula
= density compact
m1 = mass of of the sample in air
m2 = mass of the sample in water
m3 = saturant massof the sample taken from water and then cleaned
surface

t
= density of water measuring temperature t

Sintering
Scmetz Vacuum Furnace
Powder Forging
Powder Forging Die with
Flash
No Flash Die of Forging
Forging Process
Powder forging was performed on a 1600 kN friction screw
process. The pressure was controlled at 1000 1400 Mpa during
forging. The initial forging temperature of the compact was
1100C. In order to protect the compacts from oxidizing, a 4 kVA
furnace was always filled with high purity N
2
gas during heating.
After heating for 10 min, the compact was manually removed from
the furnace and put into the hot forging die quickly. In order to void
oxidation in cooling, the forged compact was dropped into oil
directly after being ejected from the mould.
Heat Treatment
Microstructure
Mechanical Properties
Conclusions
1. Powder forging of the motorcycle connecting rod is an
advanced process combining the advantages of
powder metallurgy and precision forging.
2. Fe-C-Cu-Mo alloy powder can exhibit execllent
physical and mechanical properties during
consolidating, sintering and powder forging.
3. The powder forging process of the connecting rod can
save much material, reduce the equipment capacity
and remove the excessive machining.
4. The research results of powder forging the P/M
motorcycle connecting rod can provide a good
reference to the powder forging of automobile
connecting rods.
References
1. Guangchun Wang and Guoqun Zhao,Powder
Forging of a Motorcyle Connecting Rod,Mold &
Die Engineering Tecnology Research Center,
2001.
2. Randal M. German, Powder Metallurgy
Science.