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A family of high performance P/M materials with densities in the 7.55-7.75 g/cc range has been developed. These alloys exhibit very good dimensional control with high strength and elongation. Properties are reported.

Comparisons are made between the properties of high-density materials prepared by P/M processes and similar low-alloy wrought steels. Particular emphasis is placed on the endurance limit under rolling contact fatigue conditions. It is shown that hot-formed (HF) and high fatigue alloy (HFA) P/M steels exhibit excellent rolling contact fatigue (RCF) properties which recommend them for high performance applications such as cam lobes, parking gears, transmission sprockets and planetary pinion gears. If P/M hopes to invade the high end of the gear market, the industry must satisfy a number of critical conditions: 1 Properties, particularly contact fatigue properties, must approach or match those of cut gears. 2 Tolerances and AGMA Classification must equal cut gears. 3 We must be cost competitive. This paper will discuss some of the work being done to push P/M gear properties to the next level.

Although P/M part producers have been supplying 410 and 316-base stainless steel parts for almost fifty years, P/M versions of these materials have been excluded from many moderate to severe applications due to their marginal corrosion resistance. There have been a number of efforts targeted at improving P/M stainless corrosion properties but performance comparable to the wrought stainless products has not yet been achieved. The work reported here discusses corrosion and mechanical properties obtained for modified steel alloys which have shown significantly better resistance to corrosion in simulated sea water (5% NaCl solution) while maintaining reasonable physical and mechanical properties.