Systems and methods to produce forged powder metal parts with transverse features

Abstract

Systems and methods produce forged powder metal parts respectively comprising a transverse feature. A system may comprise a powder metal die, a sintering oven, a forging apparatus, a core material, and a powder metal. The powder metal die may receive and compact the core material and the powder metal to form a compacted powder metal part with at least a portion of the core material embedded therein to define a transverse feature in the compacted powder metal part. The sintering oven may receive and sinter the compacted powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during sintering. The forging apparatus may receive and forge the sintered powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during forging with the embedded core material being removable from the forged powder metal thereafter.

1 . A method of producing a forged powder metal part comprising a transverse feature, the method comprising:
 providing a powder metal die;   positioning a core material in the die;   filling the die at least partially with a powder metal to at least partially cover the core material with the powder metal;   compacting with the die the powder metal to form a compacted powder metal part with at least a portion of the core material embedded therein, wherein the embedded core material defines a transverse feature formed in the compacted powder metal part;   sintering the compacted powder metal part to form a sintered powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during the sintering of the compacted powder metal part;   forging the sintered powder metal part to form a forged powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during the forging of the sintered powder metal part; and   removing the embedded core material from the forged powder metal part.   
     
     
         2 . The method of  claim 1 , wherein the core material is frangible. 
     
     
         3 . The method of  claim 2 , wherein the frangible core material is sufficiently brittle so as to be at least partially pulverized during the forging of the sintered powder metal part. 
     
     
         4 . The method of  claim 2 , wherein the frangible core material is at least partially broken during the forging of the sintered powder metal part. 
     
     
         5 . The method of  claim 4 , wherein the frangible core material comprises a degree of resiliency sufficient such that the at least partially broken frangible core material maintains the definition of the transverse feature during the forging of the sintered powder metal part. 
     
     
         6 . The method of  claim 1 , wherein the core material comprises at least one of graphite and ceramic. 
     
     
         7 . The method of  claim 1 , wherein the core material does not melt, vaporize, infiltrate, or otherwise dissipate during the compacting of the powder metal, the sintering of the compacted powder metal part, and the forging of the sintered powder metal part, and any combination thereof. 
     
     
         8 . The method of  claim 1 , wherein the core material is positioned in the die prior to the filling of the die with the powder metal. 
     
     
         9 . The method of  claim 1 , wherein the core material is positioned in the die during the filling of the die with the powder metal. 
     
     
         10 . The method of  claim 1 , wherein the embedded core material is removed from the forged powder metal part via at least one of a shaking, a reaming, a brushing, and an air blowing of the forged powder metal part. 
     
     
         11 . The method of  claim 1 , wherein the transverse feature comprises a depression of any one or more shapes, sizes, and dimensions in the forged powder metal part. 
     
     
         12 . The method of  claim 11 , wherein the transverse feature comprises at least one of a hole, a groove, a passage, a recess, an indentation, a thread, a cavity, an undercut, a crosscut, and an impression. 
     
     
         13 . The method of  claim 1 , wherein the forged powder metal part comprises a connecting rod of a reciprocating piston engine and the transverse feature comprises a lubricant passage between a crank end and a piston end of the connecting rod. 
     
     
         14 . The method of  claim 13 , wherein the lubricant passage connects the crank end and the piston end of the connecting rod so as to permit passage of a lubricant there-between. 
     
     
         15 . A method of producing a forged powder metal part comprising a transverse feature, the method comprising:
 providing a powder metal die;   positioning a frangible core material in the die;   filling the die at least partially with a powder metal to at least partially cover the frangible core material with the powder metal;   compacting with the die the powder metal to form a compacted powder metal part with at least a portion of the frangible core material embedded therein, wherein the embedded frangible core material defines a transverse feature formed in the compacted powder metal part;   sintering the compacted powder metal part to form a sintered powder metal part, wherein the frangible core material remains embedded therein and does not melt, vaporize, infiltrate, or otherwise dissipate during the sintering so as to maintain the definition of the transverse feature during the sintering of the compacted powder metal part;   forging the sintered powder metal part to form a forged powder metal part with the frangible core material remaining embedded therein to maintain the definition of the transverse feature during the forging of the sintered powder metal part; and   removing the embedded frangible core material from the forged powder metal part.   
     
     
         16 . A system to produce a forged power metal part comprising a transverse feature, the system comprising a powder metal die, a sintering oven, a forging apparatus, a core material, and a powder metal, wherein:
 the powder metal die is operable to receive and compact the core material and the powder metal to form a compacted powder metal part with at least a portion of the core material embedded therein, wherein the embedded core material defines a transverse feature formed in the compacted powder metal part;   the sintering oven is operable to receive and sinter the compacted powder metal part to form a sintered powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during a sintering of the compacted powder metal part by the sintering oven; and   the forging apparatus is operable to receive and forge the sintered powder metal part to form a forged powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during a forging of the sintered powder metal part by the forging apparatus,   wherein the embedded core material is removable from the forged powder metal.   
     
     
         17 . The system of  claim 16 , wherein the core material is frangible and is at least partially broken during the forging of the sintered powder metal part. 
     
     
         18 . The system of  claim 17 , wherein the frangible core material comprises a degree of resiliency sufficient such that the at least partially broken frangible core material maintains the definition of the transverse feature during the forging of the sintered powder metal part by the forging apparatus. 
     
     
         19 . The system of  claim 16 , wherein the core material does not melt, vaporize, infiltrate, or otherwise dissipate during the compacting of the powder metal, the sintering of the compacted powder metal part, and the forging of the sintered powder metal part, and any combination thereof. 
     
     
         20 . The system of  claim 16 , wherein the core material comprises at least one of graphite and ceramic.