Case Study: Inner-Plate Sprocket Assembly

Process: Conventional Press & Sinter (PM)

Material: FN-0208-30 nickel steel

Density: 6.7 g/cm³ minimum

Induction-hardened sprocket teeth

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End Use and Function

The assembly fits intake and exhaust cam phasers in a dual-overhead-cam engine. It transfers chain-driven torque, acts as a cover plate, provides lock-pin engagement, and pilots rotation between the phaser assemblies and camshaft nose.

Fabrication

Simplified compaction tooling forms the toothed hub and flange with improved tooth-to-flange runout. Automated handling transfers compacted parts to continuous-furnace sintering. Grinding, machining, deburring, induction hardening, boring, milling, threading, bushing and pin installation, and ultrasonic cleaning complete the component.

Results

The PM route produces a lighter component with substantially less waste than machining from a forging or casting. Hardened teeth provide the required strength and wear resistance while the streamlined tool stack supports dimensional capability.