Capabilities

The MetalKraft Process Can Make You a Better Contender in Your Industry

MetalKraft uses superior integrated computerized manufacturing systems so we are more efficient throughout the ordering, production and just-in-time shipping process. Our efficiency means you are more efficient. And better efficiencies translate into better profits. Our commitment to innovation allows us to offer “job shop” service, with the added benefit of high-volume capacity. Our modern 50,000 sq. ft. plant is located in Wellsboro, PA.

You’ll benefit from MetalKraft’s

  • Value-Added Individualized Process
  • Exceptional Customer Service
  • Cost- and Time- Saving Efficiencies
  • Innovation that finds you just what you need
box-processbox-materialsbox-equipmentbox-secondary

Process

The Smart Science Powering our Powder Metallurgy Process

MetalKraft uses a revolutionary highly developed method to manufacture precision metal parts so you get the best parts at the best price with the quickest possible delivery.  The process involves mixing elemental or alloy powders, which are then compacted in a die. The resulting shape is sintered in an atmosphere-controlled furnace to convert mechanical bonds into metallurgical bonds. Our process is “chip-less” process, and the Power Metal uses roughly 97% of the starting material in the finished part, again a cost efficiency that helps you.

Your MetalKraft Advantage

pm processModern production technology can achieve a wide range of powder metal densities, so steel, stainless steel or bronze parts can now be used in an increasing number of applications. For you, this means exceptional quality at an exceptional cost. Consider these advantages of the MetalKraft powder metal process:

  • Excel at producing multi-level, complex parts
  • Eliminates or minimizes machining
  • Maintains close dimensional tolerances
  • Permits a wide variety of alloy systems
  • Part to part repeatability
  • Manufacture of complex shapes impractical with other processes
  • Exceptional know-how, timeliness and customer service

The Three-Step Process

Mixing

Elemental, partially alloyed or pre-alloyed metal powders are first blended with lubricants to produce a homogeneous mixture.

powder process

Compacting

A controlled amount of a mixed powder is gravity fed into a precision die and then compacted. Compaction occurs at room temperature, at a pressure range of 25-50 tons per square inch. Compacting the loose powder produces a “green compact” which, with conventional pressing techniques, has the size and shape of the finished part when ejected from the press. Green compacts have sufficient strength for in-process handling. Typical compaction techniques use rigid dies, set into mechanical or hydraulic presses.

Compaction Tooling

compaction-tooling

Compaction Cycle

1. Cycle Start
2. Charge die w/powder
3. Compaction begins
4. Compaction complete
5. Ejection of compact
6. Recharging of die

compaction-cycle

Sintering

furnace

Typically, the “green compact” is placed on a mesh belt which then moves slowly through a controlled atmosphere furnace. The parts are heated below the melting point of the base metal, held at the sintering temperature, then cooled. Basically a solid state process, sintering transforms compacted mechanical bonds between powder particles into metallurgical bonds. Typical sintering temperatures for ferrous based metals range from 2050- 2100 degrees F.
Standard cycle times range from 2-3 hours.

Conventional Furnace Profile

furnace-diagram

Materials

Iron Steel

Iron Steel chart

Copper Steel

Copper Steel chart

Nickel Steel

Nickel Steel chart

Stainless Steel

Stainless Steel chart

Brass, Bronze, Copper

Brass, Bronze, Copper chart

MPIF Reference Tolerance Guide

Characteristic

Length
Inside Diameter
Outside Diameter
Concentricity
Flatness on Ends
Parallel of Ends

Practical

±.005
±.002
±.002
.006
±.002
±.0015

Possible

±.003
±.001
±.001
.004
±.001
±.001

Equipment

Presses

Capacity of presses range from 12-ton to 550-ton single level and multi-action presses allowing up to a 7 level part.
gasbarre-press
(Qty) & Size
(1) 500 Ton- Cincinnati Multi-action press
(1) 200 Ton- Cincinnati Multi-action press
(3) 60 Ton- Gasbarre Multi-action presses
(2) 60 Ton- Gasbarre Single action presses
(4) 30 Ton- Gasbarre Single action presses
(1) 20 Ton- Gasbarre Single action press
(2) 15 Ton- Gasbarre Single action presses
(3) 12 Ton- Gasbarre Single action presses
(6) 2 Ton- Stokes Single action presses

Sintering Ovens

furnace
(Qty) & Size
(3) 18 inch Sinterite Ovens
(3) 12 inch Sinterite Ovens

Quality Control Equipment

deltronics-qa-optical-comparator
Deltronics DH216 Optical Comparator
Wilson/Rockwell hardness tester
Dillion Load Tester

Secondary Operations

Secondary operations include:

Assembling
Burnishing

  • Ferrous Structural; Ball size, roller burnish for size control and surface finish

Deburring

  • Vibratory: All materials; Remove sharp edges related to punch and die tooling

Finishing

    • Coating Oil Dip: Ferrous; Corrosion resistance
    • Plating (Copper, Nickel, Cadmium, Zinc, Chromium): Ferrous; Corrosion resistance & appearance
    • Welding: Feerrous, 6.8g/cm3 min. density; Make assemblies from two or more parts
    • Black Oxide: Ferrous, Resin Impregnated; Corrosion resistance; Paint base

Heat Treating

      • Quench & Temper: Ferrous Structural; Improves strength and hardness
      • Steam Treat: Ferrous; Make surfaces hard and wear resistant; Improves corrosion resistance and seal porosity

Impregnation

      • Oil: Bearings; Makes bearings self-lubricating
      • Resin: Structural; Improves machinability; Prepares surface for plating with metals; Seal parts gas or liquid right; Provide lubrication
      • Vacuum

Infiltration

      • Ferrous; Improves strength; Seals parts gas or liquid tight
      • Structural; Prepares surface for plating with other metals; Improves ducttility and machinability

Machining

      • Drilling/Tapping: All materials; To install set screws or assembly fasteners
      • Grinding: All materials; Remove stock; Make faces flat and parallel; Improves surface finish and dimensional tolerances
      • Milling: All materials; Form undercuts or slots
      • Turning: All materials; Machine to exact tolerances; Form undercuts or features not possible with compaction tooling

Mechanical Surface Treatments

      • Glass Beading: All materials; Clean/improve surfaces
      • Wire Brush: All materials; Clean/improve surfaces
      • Sanding/Tumbling/Vibratory Finishing: All materials; Clean/improve surfaces
      • Shot Peening: Ferrous Structural & Forgings; Improve surface fatigue life

Repressing

      • Coining: All materials;Densification, modify surface shape, provides dimensional control
      • Sizing: All materials; Provides dimensional control

Steam Treating

The Powdered Metal Advantage

Modern production technology can achieve a wide range of powder metal densities, so steel, stainless steel or bronze parts can now be used in an increasing number of applications. For you, this means exceptional quality at an exceptional cost.

Learn More >

Superior Quality & Innovation

A leader in custom, high-quality, ISO-compliant precision powdered metal parts since 1983.

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