Fatigue design of sintered con-rods

Within an international research program con-rods from the alloy Fe-1.5-Cu-0.6C, quenched and tempered, with densities mostly over 7.0 g/ccm in the highly stressed areas were developed and pressed in the single sintering technique. The PM' tooling for the compaction-sinter-size route was manufactured after extensive FEM and experimental stress analyses. After successful fatigue testing, the con-rods achieved final engine testing without any failures. The test duration corresponded to 150.000 to 300.000 km normal european operational service.