Fabrication

This unique iron–copper (FC-0200-24) six-level component, with 5° helical pulley teeth, has a 50-micrometre surface-profile tolerance, which requires tight tool-wear control. The part is formed net shape except for the inside diameter, threads, one bearing face, and two stamped flanges that are added using capacitive-discharge welding, which allows for precise control of the gap between the flanges and the teeth.

Results

Conventional PM was chosen as the fabrication method because it offered far better precision than the die-cast alternative at a competitive price.