Stepped Sintered Member With Brazed Recessed Corner Densification
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Solution Overview
Problem
Sintered members formed by sintering powder compacts with stepped parts often suffer from cracks and insufficient density in the recessed corner parts, leading to strength deficiencies.
Innovation Solution
A sintered member and manufacturing method where a brazing material, such as a Cu—Ni—Mn-based material, is applied to the surface of the recessed corner parts of the powder compact before sintering, allowing the molten brazing material to penetrate gaps between the metal powder particles, thereby eliminating cracks and density issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a powder compact with a stepped part is molded using conventional methods, then the basic structure is formed, but cracks and insufficient density occur in the recessed corner part leading to strength deficiency
Solution Approach 1:
A brazing material is applied in advance to the recessed corner part of the powder compact before sintering. This preliminary action ensures that the defect-prone area is pre-treated with a material that will fill cracks and improve density during the sintering process, thereby preventing strength deficiency in the final sintered member
Solution Approach 2:
A brazing material is introduced as an intermediary substance between the metal powder particles in the recessed corner part. This brazing material acts as a mediator that penetrates gaps and fills defects during sintering, improving the density and strength of the problematic area without affecting the overall compact structure
2Ease of manufacture
If a single powder compact is used without additional materials, then the manufacturing process is simple, but cracks and insufficient density occur in the recessed corner part
Solution Approach 1:
Instead of modifying the entire powder compact, the brazing material is applied locally only to the recessed corner part where cracks and insufficient density occur. This localized approach maintains the simplicity of the overall manufacturing process while specifically addressing the strength issue in the critical area
Solution Approach 2:
The invention creates a composite structure by combining the metal powder compact with a brazing material in the recessed corner part. This composite approach allows the brazing material to fill defects and improve strength locally, while the rest of the compact maintains its original simple structure and manufacturing process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively suppresses strength deficiencies in sintered members by eliminating cracks and ensuring sufficient density in the recessed corner parts, thereby enhancing the overall strength and performance of the sintered member.
Implementation Method 1
a brazing material penetrates gaps between sintered metal powder particles
Implementation Method 2
a molten brazing material penetrates gaps between metal powder particles
Data Source
AI summary
A sintered member according to an aspect of the present disclosure includes a single powder compact made of a metal powder and having a stepped part, the powder compact being obtained by sintering. At a surface of a recessed corner part of the stepped part, a brazing material penetrates gaps between sintered metal powder particles.