Case Study: Inlet Flange

Process: Conventional Press & Sinter (PM)

Material: SS-409LNi ferritic-martensitic stainless steel

Final density: 7.1 g/cm³

Weight: 2.12 kg

Service temperature: 300-700 °C

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End Use and Function

The inlet flange serves in a diesel-engine exhaust after-treatment system as a V-band coupling and as a fastening point for two exhaust-gas sensors.

Fabrication

The large, high-density stainless steel flange is compacted hub-side up with contoured punches, die surfaces, and a matched feed shoe. After delubrication, hydrogen-atmosphere sintering establishes final density. Grit blasting precedes single-chucking machining of the V-band groove, faces, bores, and radial holes. The contoured hub and flange support a seamless welded joint to a cylindrical housing.

Results

The PM design integrates multiple functions that would otherwise require separate components. Its weldability, heat resistance, strength, and corrosion resistance support demanding under-hood service while near-net-shape production manages a large and complex geometry.