Various processes and apparats have been devised in the prior art so as to increase the density of sintered powder metal article. For example, U. S. Patent No. 3,795,129 relates to a method of forging a sintered article having a high density which method comprises pre-heating the forging tool of a forging machine and heating a preshaped powdering article and forging said heated preshaped powdery article by said pre-heated tool. f U. S. Patent No. 3,874,049 teaches a method of forming powder metal parts having a bearing surface wherein a sintered preform is cold formed and during such forming, shear forces are applied to the surface of the preform where the bearing surface is desired by causing a moveable die to penetrate and wipe along said surface of the area of the preform.

Moreover, U. S. Patent No. 4,059,879 relates to a method of partially densifying a selected surface portion of a sintered porous powder metal element while applying restraining pressure to other selected portions of said element in order to inhibit growth and cracking of said element during the partial cold deformation thereof. This method was described in the production of annular bearing rings and specifically required the application of restraining pressure.

Moreover, U. S. Patent No. 4,428,778 relates to a process for producing metallic chromium sheets from metallic chromium powders comprising a step of rolling metallic

chromium powders, a step of sintering rolled sheets thus obtaining a temperature in the range of 900°C to 1400°C, a step of rerolling the sintered sheets with a reduction range from 5 to 50% and a step of annealing the rerolled sheets.

In many of the prior art processes and apparats including those described above the surfaces are densifie by applying a rolling cylinder or the like against the sintered powder metal article so as to densify the surface. In particular, such prior art devices generally include a"line"of contact between the densifying tool and the sintered powder metal article. More particularly in one arrangement of the prior art the densifying tool is pressed up against the sintered powder metal article which is to be densifie such that the axis of rotation of the densifying tool and the rotating sintered powder metal article are generally parallel and the densification occurs along"a line"of contact. Generally speaking since such prior art sintered powder metal article are densifie along"line"of contact high densifying forces are required which therefore result in lower tool life.

It is an object of this invention to provide an improved method of densifying a sintered powder metal article.

It is a further aspect of this invention to provide a method of densifying a sintered powder metal article by point contact.

It is yet another aspect of this invention to provide a method of densifying a sintered powder metal article with a tool having a point for pressing and traversin said sintered powder metal article so as to densify the surface of said sintered powder metal article traverse by said point.

It is a further aspect of this invention to provide a method of densifying a sintered powder metal article comprising: blending carbon, alloys and iron; pressing said blends so as to produce a compact; sintering said compact to produce a sintered powder metal article; densifying said sintered powder metal article at ambient temperature by relative motion between said article with the tool having a point for pressing and traversin said article to define a densifie surface.

It is another aspect of this invention to produce an apparats for defining a sintered powder metal article comprising: (a) a tool having a point for contacting said sintered powder metal article; (b) means for generating relative motion between said tool and said articles for pressing said tool into said articles so as to scribe a densifie surface unto said sintered powder metal article.

It is another aspect of this invention to produce a tool for densifying a sintered powder metal blank, said tool having an edge for contacting said article at a point.

Drain% vs These and other objects and features shall now be described in relation to the following drawings: Figure 1 is a representative drawing of densifying by using rollers along a line of contact.

Figure 2 is a representative view of densifying by point contact.

Figure 3 is a representative view of the workpiece and rolling tool.

Figure 4 is a further representative view of the workpiece and rolling tool illustrating point contact densification.

Figure 5 is an end view of figure 2.

Figure 6 is a representative view of densifying a sintered powder metal article in a lathe.

Figure 7 and 7a is a representative view of the rolling tool used in figure 6.

Figure 8 is a top plan view of a gear illustrating point contact densification along an end of a sintered powder metal blank.

Figure 9 is a side view of a gear of figure 6.

Figure 10 is a cross-sectional view of figure 8 illustrating the use of a conical tool.

Figure 11 is a representative drawing of producing a race.

Figure 12 is a representative drawing of a sprocket gear being densifie in a variety of ways in accordance with this invention.

Figure 13 is a further representative drawing of a sprocket gear being densifie.

Figure 14 shows concave densification.

Figure 15 shows convex densification.

Figure 16 shows the use of two densifying tools.

Figure 17 is a chart of radial closure vs depth.

Figure 18 is a point contact densification limit diagram.

Description of Invention Like parts will be given like numbers throughout the figures.

The durability of powder metal surfaces is generally limite. It has been shown that this durability can be greatly improved by means of a combination of cold work and heat treatment. Such techniques have been extensively covered in the past and include methods of cold working by utilizing line contact tools namely tools that contact the work along a line

such as is generally used by rollers. Figure 1 is a representative view of rollers used to densify along a line of contact 3. When rollers are used to densify along a line it is generally necessary to keep both the axis of rotation, the roller 5 and the workpiece 7 namely the sintered powder metal article parallel so as to optimize such densification. Furthermore high pressures are required to achieve the necessary densification since the pressure must be exerted over a"line 5". Accordingly the requirement of parallel sides and relatively high pressures are disadvantageous as they require more accuracy and lower tool life in order to impart the necessary densification. Furthermore quite often distortion can occur because of the density variation of the workpiece which yields under the stress developed by that processing loads. Such contact area can be minimized by the use of"point contact"to be described herein.

Figure 3 shows a workpiece 2 which generally comprises a sintered powder metal article to be densifie by a tool 4 having a radius 6. The radius 6 is used to roll the surface 8 of the workpiece 2. The sintered powder metal article 2 rotates about an axis of rotation 10 in the direction A while at the same time the tool 4 is pressed radially into the surface 8 so as to define a point of contact 12 between the radius 6 and surface 8 and at the same time the tool 4 traverses or moves axially relative the workpiece 2 so as to"scribe"a densifie surface 14 as shown in Figure 4.

Since the densification occurs as a point or area or region of contact rather than a line of contact lower forces can be utilized which results in longer tool life. Figure 2 is a representative view of point contact. Under magnification the point of contact between the tool and workpiece 2 may actually appear as a generally round indentation or area 9, elliptical or oval indentation 11 or curved indentation or area 13 (particularly if the hollow cone tool 80 is used).

Accordingly the contact area is minimized by the use of point contact. The radius 6 shown in Figure 3 is used to roll the surface of the workpiece or sintered powder metal article 2. The geometry that supports the radius and delivers the processing loads can vary according to the application. The simples form of tool comprises a disc shown in Figures 7 and 7A with a radius 6 (as shown as r on the drawings) on the outside diameter 16. The

tool 4 can be pressed into the surface 8 of the sintered powder metal article at a suitable depth traverse across the surface densifying as it goes. The point contact tool accordingly presents a radius 6 or point of contact which is free to rotate and is driven by frictional forces. Such process can be carried out dry or wet (by utilizing a lubricant).

Figures 6 and 7 illustrate one embodiment of the apparats which comprises a lathe 50 having a chuck 52 for holding a workpiece such as the gear shown in Figure 6. The lathe inclues a cross slide 54 and compound solide 56 with tool holder 58 holding the tool 4 having the radius 6 or point of contact 6. The tool 4 is adapted for rotational movement within the tool holder 58.

In one embodiment the sintered powder metal article comprises a gear 60 shown in Figure 8. Such gear 60 may be held in place by the chuck 52 in the manner well known to persons skilled in the art and the compound slide 56, and cross slide 54 adjusted so that the tool 58 will contact the end 62 of the gear 60. Thereafter the tool 4 will be pressed a suitable depth (or closure) into the end face 62 of gear 60. As the chuck 52 with the sintered powder metal article 60 rotates about an axis of rotation 10 the point of contact 6 is pressed against end face 62 so as to scribe a circular region 64 starting from the outside portion of the gear 60 at the same time the tool 4 traverses or is moved radially inwardly towards the axis of rotation so as to define a densifie surface 66. In another embodiment of the invention the sintered powder metal article 2 can rotate in the lathe and the tool 58 adjusted so as to present the tool 4 to be radially pressed into the cylindrical surface of the workpiece and densify the surface as shown in Figure 4.

Alternatively conical surfaces of a powder metal article may be densifie by pressing the tool 4 a sufficient depth by radially and axially rotating sintered powder metal article at the same time moving the tool 4 so as to traverse both radially and axially along the conical surface of a sintered powder metal article so as to densify same.

Accordingly the process described herein is well suited for programmable lathes such as CNC machines. Although the invention has been described herein in relation to the lathe shown in Figures 6 and 7 other machines can be used so that the tool 4 moves while the

workpiece 2 is stationary. For example, the gear 60 shown in Figure 13 inclues root portions 68, flank portions 70 and tip 72. Accordingly the gear 60 may be held stationary and the tool pressed radially into the root portions 68 as shown in Figure 13 and then the tool 4d is traverse across the width 74 of the teeth so as to densify the root regions 68. Apparats and tools may be designed so that a number of root regions may be simultaneously densifie. Alternatively the tools may be stationary and the gear 60 move axially through a series of tools 4. The number of root regions 68 of gear 60 that may be densifie will depend on the size of the tools designed. Accordingly the gear or the tools may be indexed so as to rotate and thereby sequentially densify several root regions at once.

Accordingly programmable lathes such as CNC can be used so as to eliminate or produce tapers that are densifie or densifying flat faces such as for example thrust faces of a cone.

Furthermore, figure 11 illustrates the use of a method so as to produce ball bearing races. Again the workpiece 2 rotates in the direction of rotation A about an axis of rotation 10 and the tool 4 traverses in the direction of B so as to produce a ball bearing race. This method is different from that shown in U. S. Patent No. 4,059,879 which does not shown the workpiece traversin relative to the rotating workpiece. Furthermore, the invention describe herein does not require use of restraining pressure which was necessary in U. S. Patent No.

4,059,879.

By utilizing a smaller contact area, smaller rolling forces can be used to densify a surface or alternatively larger contact stresses are generated which can result in larger effective densification when compare with densifying by the use of rollers having a line of contact. Moreover, by point densification each element of material of a workpiece 2 is processed with a minimum number of stress reversas which means that greater densification can be achieved. This can be further enhanced by the use of different radii at the contact point each developing a maximum sheer stress at different depths.

Moreover the method described herein can be applied to nonrotational geometry such as grooves and gear root forms as previously described.

Moreover, thrust faces can be densifie and the rolling speed adjusted to maintain efficient action as the tool changes its radius at the contact point.

Moreover, figure 10 illustrates the use of a hollow conical tool 80 which presents a point of contact that can be used to densify an internal annual surface 84. Such conical tool 80 rotates about an axis of rotation 86 and sufficient force is generated through the use of bearings 88 so as to densify the surface 84. The point of contact of the conical tool 18 is generated by the rounded circular edge 82 of the conical tool 80. The point of contact or indentation may appear as shown by 13 in figure 2.

The process described herein requires that the material being processed have some elasticity and formability. The method can be used as described herein to generate the high pressure and reduce stress cycles and therefore it can be used over a wide range of materials.

For example, the powders used for sintering can be either prealloyed powder metal materials, partially prealloyed powder metal materials, substantially pure iron with the addition of ferro alloys, as well as the use of elemental blends which possess unavoidable impurities. Typical powder blends that can be used with the process described herein to produce sintered powder metal articles having the following compositions, namely: 0-0.8 % Carbon 0-4.0% Chromium 0-4.0% Manganese 0-4.0% Molybdenum 0-4.0% Nickel 0-4.0% Vanadium 0-4.0% Copper 0-4.0% Silicon 0-1.0% Phosphorous with the remainder being iron and unavoidable impurities.

However, the compositional range described above is included as an example only and not to be construed as being limited in nature.

Accordingly, the method described herein can be used to densify sintered powder metal articles by blending carbon, alloys, iron; pressing said blend so as to produce a compact; sintering said compact to produce a sintered powder metal article; densifying said sintered powder metal article at ambient temperature by relative motion between said article with the tool having a point for pressing and traversin said article to define a densifie surface.

Moreover, thrust faces can be densifie and the rolling speed adjusted to maintain efficient action as the tool changes its radius at the contact point.

Moreover, by utilizing the method herein densities up to 7.8 g/cc can be achieved depending on the depth of pressing (ie the closure) the tool 4 into the workpiece 2.

Typically, the closure can be 5 thousandths of an inch.

Furthermore, figure 12 is another representative drawing of a sprocket gear 60 being densifie in a variety of ways in accordance with the teachings of this invention: 1. the tool 4a shows that a face 61 can be densifie by traversin the point contact and compensating for rolling speed by CNC programming; 2. the tool 4b shows that conical features can be rolled; 3. the rolling tool 80 can be designed to reach into areas where access is limited; 4. the tool 4c can be used so that bores and counterbores can be densifie; 5. complex features may also be densifie as shown in figure 13 where tools 4d, 4e and 4f densifies involute tooth, roots and tips, and pitch respectively;

6. curved surfaces such as concave and convex surfaces could be densifie as shown in figures 14 and 15 respectively.

The point contact relies on relative motion only so that by the use of a series of tools the process could make use of the part movement relative to the tool; for example progressive densification incorporated into coining. Direction of rotation is not important allowing operations to be simultaneously carried out on the unused side of the workpiece during a turning operation.

Some Avantages of the Invention Described Herein Include: 1. High contact pressures with small applied force means more uniform densification of PM structures.

2. The forces required are brought within range of normal CNC lathe turret forces.

3. Genereally speaking any geometry that can be produced by CNC means can be densifie in this way.

4. The process is more controllable because the surface can be machine for precise location, immediately prior to densification.

5. Fewer stress reversas means less"damage"to the structure.

6. Some applications have indicated that the degree of sliding in the tool action is important to the level of densification. This can be controlled by presenting the tool with a pitch or alignment error such as shown by tool 4a in figure 12 (i. e. the tool is not normal or perpendicular to the axis of the workpiece or face as shown in figure 3).

7. The force required to roll a surface can change as the traverse proceeds. This indicates that wrong action is taking place and that the leading radius should be

modifie. The leading and trailing rolling forces can be balance by varying the radii at those locations.

8. There is no dwell required as with the case 4 rolling by line contact. For example, if we look at figure 2, two rollers we used so that there is a dwell of 180°. By densifying by point contact there is no dwell, and therefore the rates of rolling are much higher than with line contact.

9. The rolling tools are reusable after regrind of the form.

10. The process can be carried out dry because of the fewer number of working parts.

11. The localized closure of porosity can reduce/anticipate heat treatment distortion.

12. By varying the number of rolls and also the progression of radii r at the tips, greater depths of densification can be obtained than that shown in the prior art. This is illustrated in figure 16.

For example, two or more tools 4L and 4S used are shown in Figure 16. Generally speaking the larger the radius rL of a tool 4L used the greater the depth of densification for the same depth of penetration or closure. However it has been found that if a second tool 4S iS used to densify by point contact after using a tool 4L to densify by point contact the<BR> effect or depth densification is greater than if only one tool 4S was used. It is speculated that the reason for this is that once the surface has been densifie by tool 4L the"pores"in the PM part have been collapsed and therefore the effect of densification of tool 4S iS deeper<BR> than if only one tool 4S was used for the same closure.<BR> <BR> <P> Example Figures 17 and 18 represent data collecte from densifying a sintered powder metal part having a sintered density of 7.0 g/cc which was then point contact densifie in accordance with the invention described herein to cause sub-surface densification.

Figure 17 shows for example that starting from a sintered PM part having a core density of 7.0 g/cc, a radial closure of 0. lmm would produce a densifie sub-surface of 7.8 g/cc to a depth of approximately 0.4mm Furthermore, Figure 18 is one example of the maximum limit of point contact densification for a particular system. For example, if we use a tool radius of l/2mm and a radial closure of 2mm (so as to get a product of l/2 x 2 = lmm2) the maximum feed for effective densification is just under 1.4mm/revolutions. If a tool radius and radial closure is used which produces a value above the curve in figure 18 surface exfoliation or surface damage is liable to occur. In other words controls set in excess of the maximum limits generally result in nonuniform, densification and a poor surface finish.

The reference to radial closure could also refer to axial closure if the tool 4 is pressed axially into the workpiece. The tool radius in figure 18 refers to r.

Comments on Densification (for material at 7.0 g/cc with 0.4% C) as shown in Figure 18 Can achieve 0.005" radial closure in one pass.

Can achieve 0.0015" radial closure with multiple passes.

Maximum closure per pass-fixed by densification limit diagram.

The use of multiple passes generally improves the level of densification. However, too many multiple passes may cause surface exfoliation (up to around 0.004" depth).

The rolling damage which may occur can often be offset by annealing before rolling.

Depth of densification is directly related to radial closure-see graph.

There is some small dependence of tool radius (R as shown in figure 7) on densification depth-a smaller radius r promotes improved densification characteristics.

Effects of Material Condition (densitv, carbon/alloy level) Core density is expected to play a large role on closure-densification characteristics.

Carbon and alloy composition will have a minor effect densification characteristics.

Carbon and alloy composition may affect maximum absolut closure/densification levels due to inherent material plasticity and fatigue resistance.

Subsequent Heat Treatment Subsequent heat treatment will likely be required as in the case of densifying by line contact to optomize durability of the part.

Although the preferred embodiment as well as the operation and use have been specifically described in relation to the drawings, it should be understood that variations in the preferred embodiment could be achieved by a person skilled in the trade without departing from the spirit of the invention as claimed herein.