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Details....Ford's new 6R140 Six-Speed Heavy Duty Transmission

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Old 12-09-2009, 05:45 PM
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They use a fine metal powder squeeze it under somewhat high pressure in a die to form the shape. (Sintering is NOT forging) The powder has a binder in it so when its sintered (heated up to high temp) it binds together. Powdered metal parts are OK but I wouldn't make gears out of it which are under a lot of stress. Would be better off hobbing the gears and then heat treating them but that costs quite abit more than a powdered part. A gear machined from a forging or a solid piece of stock would be a lot better. Tungsten carbide inserts common in the machining industry is a good example of a powdered metal part.

Brazing is more of a term that describes a heat range. For example once you get over a certain temperature you are no longer "Soldering" a part together you are now "brazing" it together. You can braze brass, copper, steel cast iron and etc with the same low fuming bronze brazing rod and a oxyfuel torch.
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Old 12-09-2009, 10:00 PM
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PM is heavily used for gears. That is one of it's strongest applications.

Machining from solid stock is often not as strong due to grain structure issues. For a related example search the interweb on rolled threads vs cut threads.

Many parts that are sintered are also infiltrated with a lower melting metal to fill in the remaining interstices in the PM matrix.

Tungsten carbide is sintered, but is not PM as it is a ceramic. Similar process, but yet different.
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