Magnetic Compaction of Powdered Metals
We have developed a unique solution for forming accurate, dense near-net-shape parts from powdered materials. IAP’s proprietary Dynamic Metal Compaction (DMC) process gives the highest green density of any known process, allows for co-filling with multiple materials and holds tight dimensional tolerances.
Magnetic Rotors for brushless DC Motors
Using DMC compaction, we have developed a one piece rotor with a steel core and neodymium magnet ring formed simultaneously. This one piece design is enabled by the ability of the DMC process to co-fill dissimilar materials. This one piece design along with the higher densities achieved with DMC produced a rotor capable of higher speed than conventional two–piece, bonded designs.
Powder Metal Steel Ring Gear
IAP joined material blending technology with the exclusive DMC magnetic compaction process to produce a net shape prototype ring gear for GM Power Train, with an AGMA quality rating of 9. This gear achieved a density of 7.6 g/cc, excellent for a powdered metal component.
IAP can help you apply magnetic forces to form, expand and join metals. This process is called electromagnetic forming (EMF). EMF offers the following advantages: 1) reduced tooling complexity since the electomagnetic force generates the required forming pressure without hard tooling 2) higher precision and repeatability of forming operations due to lower springback and 3) improved formability in aluminum alloys which are hard to form with conventional forming approaches.
IAP has been involved in the development of EMF applications in a broad range of industries to include automotive, aerospace and food service. Some of these applications are listed below:
- Forming and assembly of aluminum automotive wheels
- Hot forming of aluminum truck wheel forgings
- Assembly of collapsible automotive drive shafts
- Expansion and reduction of high strength aluminum tubing
- Assembly of evaporators for soft serve ice cream machines