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P/M aluminium structural parts for automotive application

Aluminium-Sinterteile für die Autoindustrie
: Schubert, T.; Weißgärber, T.; Kieback, B.; Balzer, H.; Neubing, H.C.; Baum, U.; Braun, R.

Danninger, H. ; European Powder Metallurgy Association -EPMA-:
Euro PM 2004, Powder Metallurgy World Congress & Exhibition. Conference proceedings : Vienna, Austria, 17 - 21 October 2004
Shrewsbury: EPMA, 2004
ISBN: 1-89907-215-2
Powder Metallurgy World Congress & Exhibition <2004, Vienna>
Conference Paper
Fraunhofer IKTS ()

In recent years there has been a resurgence of interest in development of P/M aluminium alloys and components, especially for automotive applications. These light weight materials are expected to replace sintered iron and steel parts in automobiles in order to reduce weight, increase fuel efficiency and also reduce exhaust emission. The presentation will give an overview of the objectives of the current joint research project sponsored by the BMBF. Hypereutectic Al-Si-alloys produced by powder metallurgy are most promising because of their superior properties (hardness and strength, low thermal expansion, wear resistance) and the ability to tailor these properties for particular applications (e.g. oil pump rotors). However, it must be shown that each application is technical feasible as well as cost effective in order to introduce mass production of P/M Al-Si-alloys. In this context, the press-and-sinter P/M offering net shape and inexpensive manufacturing will be considered For the manufacturing of aluminium based P/M precision parts by pressing and sintering, suitable powder mixtures have been developed. In the last years, considerable work has been done on Al- Si base sintered alloys of near- and hypereutectic composition. These alloys are attractive for wear loaded components but also offer good mechanical properties and tailorable CTE's. Oil pump rotors are heavily loaded under operating conditions. Durability testing of P/M aluminium rotors performed in a transmission test stand showed that Alumix231 can meet the main demands on material properties (density > 95%, hardness > 130HB, strength > 250MPa, high wear resistance). In addition, the P/M aluminium pump rotors would allow to replacing previous cast iron pump housing by cast aluminium for significant weight savings of about 1 kg.