GKN Sinter Metals received two grand prizes from the Metal Powder Industries Federation (MPIF) at its annual Powder Metallurgy Design Excellence Awards. MPIF’s Design Excellence Awards recognize designs emphasizing the improved net shape, precision, innovative fabrication methods, production efficiency, sustainability contributions, and manufacturing cost reduction capable with powder metal technology.
In the automotive engine category, GKN Sinter Metals received the grand prize for its VVT rotor adapter assembly consisting of a powder metal steel rotor and adapter, used in a Chrysler V-6 engine. Utilizing a two-piece design, allows for a reduction in machining, while minimizing the material waste due to the near net shape capabilities. With GKN’s ability to form vertical slots for oil feeding, the adapter requires no machining prior to assembly. GKN is able to provide a product with very high density and tensile strength, while reducing manufacturing processes and therefore costs for the total VVT (Variable Valve Timing) system.
GKN Sinter Metals also won the grand prize in the automotive transmission category for a unitized one-way clutch (OWC) module made for the Chrysler Group LLC. The module has four powder metal steel parts (powder-forged race and cam, and two pressed-and-sintered retainer plates) as well as 22 additional parts (clips, springs and roller elements). This product is the first self-contained loose-roller OWC module for torque converter stator applications using all powder metal and powder-forged main components. The retainer plate has net shape features that cannot be formed by other manufacturing processes without major secondary operations. Selecting the powder metal process reduced production costs by 20% and increased the volume rate by 50%. Powder metal’s reliability is supported by more than 10 million OWC assemblies in the field with zero warranty claims.