Case Study: Water Pump Pulley

Process: Conventional Press & Sinter (PM)

Material: Copper steel with 1 wt.% copper and 0.3-0.6 wt.% carbon

Density: 6.4-6.8 g/cm3

Mass reduced by 14%

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End Use and Function

The pulley transfers rotational motion from a drive belt to a water-pump shaft, maintaining continuous coolant circulation and reliable engine temperature control.

Fabrication

Because only a single-level press was available, wedge and sliding-insert tooling was developed to simulate multi-level compaction. Controlled fill compensation and optimized cavity geometry balance green density. A redesigned upper relief reduces mass while retaining functional and structural requirements.

Results

The redesigned pulley is 14 percent lighter while maintaining strength requirements. Compared with machined cast or wrought alternatives, PM reduces material waste and shortens lead time.