PMG Fussen GmbH


PMG Fussen GmbH

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Amos D.,ZF Friedrichshafen AG | Delarbre P.,PMG Fussen GmbH | Lipp K.,Fraunhofer Institute for Structural Durability and System Reliability | Kaufmann H.,Fraunhofer Institute for Structural Durability and System Reliability
Proceedings of the World Powder Metallurgy Congress and Exhibition, World PM 2010 | Year: 2010

The use of P/M materials is rapidly expanding concentrating more and more on highly loaded structural parts such as synchronizer hubs, gears and sprockets, shifting forks or others. The successful implementation of P/M materials for parts with sharply notched areas depends on a reliable fatigue design. Such a design has to consider the local durability even in sharp notches taking into account the local density and the highly stressed material volume. This paper summarizes the transferability of characteristic fatigue properties derived from specimens to a real sharply notched component, a synchronizer hub made from a 4% Ni diffusion-alloyed steel (Distaloy AE) with addition of 0.6%C. This paper demonstrates and discusses the practicability of such a design method.

Rau C.,PMG Fussen GmbH | Sigl L.S.,PMG Fussen GmbH | Mork G.,Getrag | Wattenberg F.,RWTH Aachen
Fenmo Yejin Jishu/Powder Metallurgy Technology | Year: 2012

Selective surface densification is a tool for improving the mechanical properties of P/M steels, such that the requirempents for highly loaded gears can be matched. This paper describes the mamufacturing and the properties of a helical P/M gear. The gear performance was evaluated on a 3-shaft back to back test rig, on a load bearing test rig and on a sound test bench. The results of these tests are presented and compared to data obtained from solid steel gear with identical geometry and surface quality. This comparison indicates that P/M gears have a load bearing capacity and noise level which are both well comparable to solid steel gears.

Fernandez M.,PMG Fussen GmbH | Rodriguez C.,University of Oviedo | Belzunce F.J.,University of Oviedo | Garcia T.E.,University of Oviedo
Metal Powder Report | Year: 2016

Powder metallurgy is a manufacturing technology widely used, especially in the automotive sector. In order to assure the quality of these components different conventional tests are employed directly on the final product, but in order to make the mechanical characterization of sintered materials, standard mechanical tests can only be performed onto samples compacted and sintered in controlled conditions similar to the ones used in real production. The final mechanical properties of these products after compacting and sintering are the input needed to define and analyze new geometries and products. The use of the small punch test (SPT) to mechanically characterize in a direct way the final sintered products was explained in this research work and the regressions to determine the tensile mechanical properties of the aforementioned products were also developed. © 2016 Elsevier Ltd.

Delarbre P.,PMG Fussen GmbH | Dennert C.,PMG Fussen GmbH
International Powder Metallurgy Congress and Exhibition, Euro PM 2013 | Year: 2013

The bending fatigue strength of a nickel-free alloyed PM steel containing Mo prealloyed powder and a copper-mixed water-atomised iron powder was investigated with varying heat treatment. To obtain high bending fatigue, a similar high density in the surface area is necessary. The DensiForm® technology has the advantage of surface densification on the surface of the gear, low cost and high precision. This paper presents the influence of the heat treatment on the bending fatigue performance of two nickel free PM materials suitable for gears.

Schoppa A.,PMG Fussen GmbH | Delarbre P.,PMG Fussen GmbH | Schatz A.,PMG Fussen GmbH
Advances in Powder Metallurgy and Particulate Materials - 2013, Proceedings of the 2013 International Conference on Powder Metallurgy and Particulate Materials, PowderMet 2013 | Year: 2013

Insulated pure iron powder or so called "Soft Magnetic Composite (SMC)" is finding more use in electric motor applications especially in motors operating at high frequency with a three-dimensional magnetic flux path. With increasing values of operating frequency the use of SMC can contribute to a substantial decrease of specific core losses of the machine, increasing at the same time its total efficiency. In contrast to laminated cores, the manufacturing process of soft magnetic composites does not influence their final magnetic properties. These properties are homogenous and do not change after assembly of the motor. New SMC materials can outperform current laminated steel materials when measurements are done in the same conditions with similar samples. Many prejudices existing about the magnetic properties of SMC can thus be eliminated or attenuated if we respect its optimal use in adequate applications.

Sigl L.S.,PMG Fussen GmbH | Rau G.,PMG Fussen GmbH
Fenmo Yejin Jishu/Powder Metallurgy Technology | Year: 2013

During the past years, key components for synchronizing systems in manual transmission gear boxes such as synchronizer hubs and synchronizer rings have been manufactured in large quantities by P/M technology. After presenting recent developments in high strength P/M steels for advanced synchronizer hubs, this paper compares three frictional linings for synchronizer rings based on carbon-fabric, sintered friction layers and molybdenum wire-sprayed linings. Results on friction performance and life time tests are discussed in terms of pressure and sliding speed. Finally, special emphasis is given to new P/M developments such as sliding sleeves and load bearing gears. Application test results for sliding sleeves are described and discussed with respect to field test results. Eventually, the performance of surface densified helical P/M gears is outlined. Results obtained from run-time tests are presented and compared to standard wrought steel gears.

Schoppa A.,PMG Fussen GmbH | Delarbre P.,PMG Fussen GmbH | Holzmann E.,PMG Fussen GmbH | Sigl M.,PMG Fussen GmbH
2013 3rd International Electric Drives Production Conference, EDPC 2013 - Proceedings | Year: 2013

To ensure a fair comparison of magnetic properties between electrical steels and SMC the measurements should be done on samples with a similar geometry. At a certain transition point of frequency the specific core losses of SMC become lower then those of electrical steels. Thus, the application of SMC instead of electrical steels in electrical machines operating at elevated frequencies can improve their efficiency. © 2013 IEEE.

Sigl L.S.,PMG Fussen GmbH | Rau G.,PMG Fussen GmbH | Dennert C.,PMG Fussen GmbH
Fenmo Yejin Jishu/Powder Metallurgy Technology | Year: 2012

Historically, wrought steel alloys have been employed in the series manufacturing of high torque transmitting components such as transmission gears, high performance sprockets, one-way clutch races and bearing races to insure long term system reliability. Although P/M technology offers lower cost components, limitations in static, fatigue and wear properties of conventional P/M steels preclude utilization of powder metallurgy parts in these applications. To address these shortcomings, various processes to improve the properties of P/M steels by selective surface densification (SSD) have been developed during the past years. Specifically, the PMG Group developed DensiForm ®, a proprietary densification process which generates components with a fully dense surface layer in critical areas up to 1 mm deep into the part and a highly dense yet still porous core. This combination and powder metal alloying flexibility allows the production of sintered steel components which match the performance of wrought steel in highly stressed applications. Two examples, i. e. a surface densified helical gear for a gear box application and a spur chain drive sprocket are described in this paper. After describing the processing and microstructure, properties of a helical P/M gear for a passenger car gear box are presented including rolling contact fatigue data obtained on a 3-shaft back to back test rig. Finally the properties and performance data of surface densified sprockets are described.

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