Impact of copper and carbon on mechanical properties of iron-carbon-copper alloys for powder metal forging applications

Abstract

There was perceived a lack of information regarding higher strength materials for sinter-forging automotive applications. Work, therefore, was undertaken to develop new higher strength materials for sinter-forging automotive applications and to fill this lack of information. Accordingly, a connecting rod that comprises an iron-based powder metal mixture was developed. The mixture comprises between 3.01% and 3.03% by weight of copper, between 0.57% and 0.64% by weight of carbon, between 0.32% and 0.33% by weight of manganese, and about 0.13% by weight of sulfur.

1 . A connecting rod comprising: 
 an iron-based powder metal mixture, wherein said mixture comprises: 
 between 3.01% and 3.03% by weight of copper;  
 between 0.57% and 0.64% by weight of carbon;  
 between 0.32% and 0.33% by weight of manganese; and  
 about 0.13% by weight of sulfur.  
   
   
   
       2 . The connecting rod of  claim 1 , wherein said mixture consists of: 
 between 3.01% to 3.03% by weight of copper;    between 0.57% to 0.64% by weight of carbon;    between 0.32% to 0.33% by weight of manganese; and 0.13% by weight of sulfur.    
   
   
       3 . The connecting rod of  claim 1 , wherein said mixture consists of about 3.01% by weight of copper.  
   
   
       4 . The connecting rod of  claim 3 , wherein said mixture consists of about 0.64% by weight of carbon.  
   
   
       5 . The connecting rod of  claim 4 , wherein said mixture consists of about 0.33% manganese.  
   
   
       6 . The connecting rod of  claim 5 , wherein said mixture consists of about 0.13% by weight of sulfur.  
   
   
       7 . The connecting rod of  claim 1 , wherein said mixture consists of about 3.03% by weight of copper.  
   
   
       8 . The connecting rod of  claim 7 , wherein said mixture consists of about 0.57% by weight of carbon.  
   
   
       9 . The connecting rod of  claim 8 , wherein said mixture consists of about 0.32% manganese.  
   
   
       10 . The connecting rod of  claim 9 , wherein said mixture consists of about 0.13% by weight of sulfur.  
   
   
       11 . The connecting rod of  claim 1 , wherein said mixture is used in sintered-forging to create said connecting rod.  
   
   
       12 . The connecting rod of  claim 1 , further comprising: 
 a crank end;    a shank connected to said crank end; and    a pin end connected to said shank and opposite from said crank end.    
   
   
       13 . A sintered-forged connecting rod comprising: 
 an iron-based powder metal mixture essentially consisting of: 
 between 3.01% and 3.03% by weight of copper;  
 between 0.57% and 0.64% by weight of carbon;  
 between 0.32% and 0.33% by weight of manganese; and  
 0.13% by weight of sulfur.  
   
   
   
       14 . The connecting rod of  claim 13 , wherein said mixture consists of: 
 3.03% by weight of copper;    0.57% by weight of carbon;    0.32% by weight of manganese; and    0.13% by weight sulfur.    
   
   
       15 . The connecting rod of  claim 13 , wherein said mixture consists of: 
 3.01% by weight of copper;    0.64% by weight of carbon;    0.33% by weight of manganese; and    0.13% by weight sulfur.    
   
   
       16 . An iron-based powder metal mixture capable of being sintered-forged into a connecting rod, said mixture consisting of: 
 between 3.01% and 3.03% by weight of copper;    between 0.57% and 0.64% by weight of carbon;    between 0.32% and 0.33% by weight of manganese; and    0.13% by weight of sulfur.    
   
   
       17 . The mixture of  claim 16 , wherein said mixture consists of: 
 3.03% by weight of copper;    0.57% by weight of carbon;    0.32% by weight of manganese; and    0.13% by weight sulfur.    
   
   
       18 . The mixture of  claim 16 , wherein said mixture consists of: 
 3.01% by weight of copper;    0.64% by weight of carbon;    0.33% by weight of manganese; and    0.13% by weight sulfur.    
   
   
       19 . The mixture of  claim 16 , wherein said mixture is capable of being sintered-forged into a connecting rod.  
   
   
       20 . The mixture of  claim 19 , wherein said connecting further comprises: 
 a crank end;    a shank connected to said crank end; and    a pin end connected to said shank and opposite from said crank end