At PSM Industries, we make powder metal parts (or PM) that meet strict tolerances and perform reliably in demanding applications. Our Pacific Sintered Metals and PM Engineered Solutions divisions handle these parts from start to finish, combining the efficiency of powder metallurgy with precise CNC machining to deliver components that are ready for use in automotive, aerospace, industrial, medical devices, and consumer products.
What Are Powdered Metal Parts?
PM parts are formed by pressing finely blended metal powders into shape and then heating them until the particles fuse together. This process allows us to create parts that are near-net-shape, reducing material waste and machining requirements. It also opens up possibilities for producing complex geometries that would be expensive or impossible with traditional casting, forging, or machining from bar-stock.
Because of the control we have over the powders and the pressing process, the resulting sintered metal components are strong, consistent, and reliable. Once sintered, these components can undergo secondary machining to reach tighter tolerances, add features to the part that could not be included in the original PM compact, or achieve specific surface finishes.
The Powder Metallurgy Process
Here’s how we turn metal powders into precision sintered parts:
- Powder Production and Blending – We start with high-quality metal powders selected for the application. They are mixed with lubricants (typically under 1% of the mix by weight) to protect the molding tooling and to maintain consistent density.
- Compaction – The blended powder fills the mold volumetrically in a consistent manner and is then pressed at room temperature at up to 45 tons per square inch to form a “green compact.” At this stage, the part has the shape but lacks the full strength of metal.
- Sintering – The green compacts are first heated at a low temperature in a controlled atmosphere to remove the lubricant, then the temperature is increased dramatically to just below the melting point. At this elevated temperature, the metal particles quickly bond, producing sintered metal components with strength, durability, and dimensional integrity.
- Secondary Operations – Some parts are ready as-is, while others require machining to achieve tighter tolerances, add features that the PM molding process is unable to achieve, tap molded holes, or to improve a surface finish.
Machining Powdered Metal Parts
Even with near-net-shape parts, machining is often necessary. Our CNC lathes and mills can handle drilling, turning, milling, tapping, and threading. This gives customers precision sintered parts that meet their strict design specifications in a cost-effective way.
While PM parts can be machined in the as-sintered condition, the porosity inherent in the process creates an interrupted cut that can slow machining and cause premature tool wear. To improve machinability and protect cutting tools, we prepare PM parts for machining in one of three ways, depending on the application. We can include a machinability additive such as manganese sulfide during the blending step, vacuum impregnate the sintered part with polyester resin to fill porosity, or infiltrate the pores in the green compact with copper during sintering. The PSM team can discuss each of these techniques to determine which option is best suited to your part design, performance requirements, and machining needs.
Using machining only where needed keeps production efficient. It also lets us deliver parts ready for assembly with tighter tolerances and smoother surfaces than pressing and sintering alone can achieve, while still benefiting from the near-net-shape features created during the PM molding process.
Advantages of Machined Sintered Parts
Combining powder metallurgy with targeted machining has clear benefits:
- Lower material waste than traditional machined parts
- Ability to produce complex shapes with fewer operations
- Consistent mechanical properties and strength
- High accuracy for tight tolerances
Customers get parts that are reliable, consistent, and ready to perform.
Applications Across Industries
Precision sintered parts from PSM Industries appear in a wide variety of applications like:
- Automotive components like gears, bushings, and bearings
- Aerospace parts, including engine components and brackets
- Industrial machinery like gearing, sprockets, and splines.
- Medical devices and consumer products
Our team makes sure each part meets your specifications before it leaves the facility.
PSM Industries’ Commitment
Quality is non-negotiable. Every sintered metal component goes through inspection and testing to guarantee dimensional accuracy and surface quality. Our Pacific Sintered Metals and PM Engineered Solutions divisions oversee this process and work closely with customers to meet specific performance requirements.
If you need PM parts that are reliable, cost-effective, and ready for production, contact PSM Industries today. We can provide parts that meet your exact needs while saving time and material.
