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Case Study: Output Gear

Process: Conventional Press & Sinter (PM)

Material: SS-316L stainless steel

Density: 6.4 g/cm3 minimum

AGMA 7 gear quality

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End Use and Function

The six-level output gear is used in a diesel engine turbocharger, where it supports reliable operation and helps maintain the correct air-fuel mixture for optimized engine performance.

Fabrication

The component is compacted using complex tooling with adaptive features that control powder fill, transfer, and displacement. Tight inner rectangular dimensions, true-position, and perpendicularity requirements are maintained through precision processing. Rigorous contamination controls and copper-silver coupon testing verify that sulfur and chlorine are not detectable at parts-per-billion levels, protecting soldered connections from outgassing-related failure.

Results

The PM design provides a corrosion-resistant, solderable component with dependable gear performance. Near-net-shape processing supports the demanding geometry and dimensional requirements while enabling a production-ready design for diesel engine turbocharger service.

 

2026 Grand Prize winner in the Automotive-Engine category for conventional PM components

 

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