Case Studies

Providing higher quality in a critical component while reducing the cost. The Product: Large stainless steel outer support used by a manufacturer of automatic placement systems for the electronics industry. The Problem: Because the part required high strength and no magnesium, it had to be made from 316 stainless steel. The customer came to Martin because the current manufacturing technique - machining from stainless steel bar - was often distorting the component due to its cross sectional area. In addition the machining was extremely expensive. The Martin P/M Solution: To produce the part from extremely high density 316 stainless powdered metal, sintered at a high temperature in a vacuum, finished with secondary machining operations. The part was difficult because it had six different levels of thickness. We developed a complicated compacting die set that would produce the component in almost completely finished form. The die set consisted of nine separate bottom punches, with each punch individually controlled to insure the correct density for every thickness. During sintering, each component was individually stages in the vacuum furnace to maintain even heating and prevent warping. Finally, we finished the part with a number of secondary milling operations. Martin went on to produce 500-1000 parts per month, providing a reliable supply of consistent high quality components at less than one-tenth the price the custom was paying previously.
Solving a critical design problem for a leading defense electronic company. The Product: A thin-walled receptacle for a cable assembly. The Problem: The customer needed a thin consistent walled part produced in very small quantities. The design, which had been dictated by the shape of existing equipment, did not conveniently lend itself to any manufacturing process. The walls and top of the shell were so thin (.035 to .040 inch) that no casting method could fill the cavity properly and machining was prohibitively expensive. The customer's only requirement was that the assembly be metallic in order to conduct electricity. The Martin P/M Solution: Because the walls of the part were so thin, we had to make a powdered metal compound with very tightly controlled densities. Too great a density would destroy the die set, tooling that took 250 man hours to produce. The components were made from bronze, a material that flows easily, for a properly filled die cavity. After compacting, the parts were sintered, then restruck to insure an overall thickness of no more that .005 inch. Martin has been producing the assembly for over a year, in quantities of up to 500 per order.
Producing a precision high strength gear at an economical cost. The Product: as part of the primary drive train, the gear must be very precise, and withstand high stress loads and a high degree of wear. But because this was an entry level product, it had to be produced at an economical cost. The original drawings specified 4150 alloy steel. However, to machine the part from bar stock would be prohibitively expensive. The Martin P/M Solution: We chose the closest powdered metal equivalent to 4130 alloy steel, with an ultimate tensile strength of more than 150,000 P.S.I. fully hardened. The component presented two critical tooling challenges. First, the pinion and the outer gear had to be held concentric to within .002. Secondly, because of the material density required to achieve the necessary strength, the tooling would have to be produced to the very highest standard available. To get the same density in both gears, Martin developed a special tolling technique that permitted deep transfers of powder to take place simultaneously during the pressing. We sintered the compounds in a special atmosphere to maintain the tight carbon control required for strength and hardness. After sintering, the component was heat treated for added hardness. Martin has been successfully producing this component for months. The customer uses approximately 2,500 parts per month.
Martin Technologies, Inc. P.O. Box 11550 Huntsville, Alabama 35814 Telephone (256) 837-9600 Fax:  (256) 890-4175 e-mail: info@martin-tech.com "Our passion is solving your parts problems " MTI Home Page | Company Information | Toolmaking | Powdered Metal Parts | Precision Machining Assembly Services | Engineering Services | Contacts | Directions to MTI / MBT  Employment Opportunities