Powdered metal compacting

Abstract

A system and a method of making an object from powdered metal are provided. The method includes feeding the powdered metal into a first end of a die. The die is rotated to pull a first portion of the powdered metal into a pressing zone. The first portion of the powdered metal is pressed using high pressure. The die is further rotated to release the first portion of the powdered metal from a second end of the die. A second portion of the powdered metal is then pulled into the first end of the die.

What is claimed is: 
     
         1 . A method of making an object from powdered metal, the method comprising:
 feeding the powdered metal into a first end of a die;   rotating the die to pull a first portion of the powdered metal into a pressing zone;   pressing the first portion of the powdered metal using high pressure;   rotating the die further, to release the first portion of the powdered metal from a second end of the die, wherein the die rotates in one direction only; and   pulling a second portion of the powdered metal into the first end of the die.   
     
     
         2 . The method of  claim 1  further comprising, rotating the die continuously or semi-continuously. 
     
     
         3 . The method of  claim 1  further comprising, rotating a roller in a direction opposite to the direction of the die, wherein the roller is disposed adjacent to the die. 
     
     
         4 . The method of  claim 1  further comprising:
 sintering the pressed portion of the powdered metal using high temperature to form a corresponding compact portion; 
 cutting the compact portion to form an individual compacted piece; and 
 shaping the individual compacted piece to form the object. 
 
     
     
         5 . The method of  claim 4  further comprising, subjecting the individual compacted piece to secondary processing. 
     
     
         6 . The method of  claim 5 , wherein the secondary processing is forging, machining, bending, shearing, coining, milling, or any combination thereof. 
     
     
         7 . The method of  claim 1 , wherein the feeding is continuous feeding. 
     
     
         8 . The method of  claim 1  further comprising, forming a spiral ring, a planar ring, or an I-beam from the powdered metal. 
     
     
         9 . The method of  claim 1  further comprising, pressing the powdered metal under focused pressure at a high compression rate to form the object having a near uniform density. 
     
     
         10 . The method of  claim 9 , wherein the powdered metal is pressed from 10-100 tons per square inch within 1-10 seconds. 
     
     
         11 . The method of  claim 1 , wherein the powdered metal is pressed at a temperature between 20-200° C. 
     
     
         12 . A system of compacting powdered metal, the system comprising:
 a feeder configured to feed the powdered metal at a continuous or stepwise rate;   a die configured to receive the powdered metal from the feeder and to rotate about a first axis, wherein the die rotates in one direction only;   a roller disposed adjacent to the die, the roller configured to rotate about a second axis in a direction opposite to that of the die.   
     
     
         13 . The system of  claim 12 , wherein the die is configured to rotate continuously or semi-continuously. 
     
     
         14 . The system of  claim 12 , wherein the die comprises teeth along an outer edge. 
     
     
         15 . The system of  claim 12 , wherein the die is a screw-type die, configured to move axially along a plane perpendicular to the roller. 
     
     
         16 . The system of  claim 12 , wherein the die comprises a preformed sinter lock joint. 
     
     
         17 . The system of  claim 12 , wherein the die comprises a start-stop joint.