NTN Japan has developed a manufacturing technology for sintered alloy products with excellent molding accuracy and durability. The true density ratio is over 95%, and the fatigue strength is above 300 MPa, all reaching the "world's highest level" (NTN). This technology can be used to replace mechanical components such as gears, cams and sprockets that have been previously machined into sintered alloy products.
The newly developed manufacturing technology is based on the powder metallurgy method. In the powder metallurgy method, after the powder material is press-formed, it is fired at a temperature lower than the melting point of the material to form a sintering between the metal powders. The metal mold can be used to perform processing close to the product itself and its shape (near net shape), thus having the advantages of material loss and low energy consumption during processing. However, the powder metallurgy method tends to form minute pores inside, and has a problem of poor fatigue resistance as compared with cast products and die-cast products produced by a cutting method.
This manufacturing technique achieves a high-density sintered body by improving the material powder, molding conditions, and firing conditions, and lowering the molding pressure to a lower level of 6t to 10tf/cm2 (588M to 981MPa). In addition, the self-developed heat treatment technology is applied to the sintered body, so that the fatigue resistance of the sintered alloy product with the number of times of stamping and sintering is increased to 300 MPa or more. When the gear is manufactured by the sintering forming method, a gear having a strong root and a tooth surface can be manufactured. Specifically, the surface pressure strength of the tooth surface can be increased to 2 GPa or more, which is 1.5 times or more of that of the conventional product. This is expected to greatly simplify the production process of power transmission mechanical components. In the future, NTN will work with Japan Science Metallurgy to accelerate the development of sintered alloy products using new technologies.
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