An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.

An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.

A method of making a sintered part includes a step of applying a machining process to a compacted part with a tool to make a machined compacted part having a cogwheel shape, and a step of sintering the machined compacted part to make a sintered part, wherein the machining process is such that a surface of the compacted part on a side where the tool exits is supported by a plate member having a tooth pattern with same specifications as a tooth pattern of the cogwheel shape, and the tool is used to machine portions of the compacted part corresponding to tooth spaces of the plate member.

A method of making a sintered part includes a step of applying a machining process to a compacted part with a tool to make a machined compacted part having a cogwheel shape, and a step of sintering the machined compacted part to make a sintered part, wherein the machining process is such that a surface of the compacted part on a side where the tool exits is supported by a plate member having a tooth pattern with same specifications as a tooth pattern of the cogwheel shape, and the tool is used to machine portions of the compacted part corresponding to tooth spaces of the plate member.

The cutting insert may include a substrate including a first surface, a second surface, and a cutting edge. The substrate may include a hard phase and a binder phase, and the hard phase may include a first hard phase and a second hard phase. In X-ray diffraction analysis, a peak of the first hard phase may be observed on a higher angle side than a peak of the second hard phase. The second hard phase in the second surface may include a compressive residual stress of 150 MPa or more. A maximum height (Rz) in the second surface may be 0.2 to 1.5 μm. A maximum height of the cutting edge may be 2 to 30 times the maximum height in the second surface.

Provided is a sintered bearing for an EGR valve, including raw material powder including 9% by weight to 12% by weight of aluminum, 0.1% by weight to 0.6% by weight of phosphorus, 3% by weight to 10% by weight of graphite, and the balance including copper as a main component, and inevitable impurities. The sintered bearing has a structure of a sintered aluminum-copper alloy. The sintered bearing further includes free graphite distributed in pores formed so as to be dispersed.

Provided is a sintered bearing for an EGR valve, including raw material powder including 9% by weight to 12% by weight of aluminum, 0.1% by weight to 0.6% by weight of phosphorus, 3% by weight to 10% by weight of graphite, and the balance including copper as a main component, and inevitable impurities. The sintered bearing has a structure of a sintered aluminum-copper alloy. The sintered bearing further includes free graphite distributed in pores formed so as to be dispersed.

Provided is a method for manufacturing a sintered component, which can suppress occurrence of edge chipping when a through-hole is formed in a powder-compact green body and also has a good productivity. The method for manufacturing a sintered component includes a molding step of press-molding a raw material powder containing a metal powder and thus fabricating a powder-compact green body; a drilling step of forming a hole in the powder-compact green body using a drill; a sintering step of sintering the powder-compact green body after drilling, wherein the drill used for drilling has a circular-arc shaped cutting edge on a point portion thereof.

It has been unexpected found that the machinability and corrosion resistance of powder metal parts can be greatly improved by incorporating calcium aluminoferrite powder, such as naturally occurring brownmillerite powder (Ca.sub.2(Al,Fe).sub.2O.sub.5), into the part. Improved machinability is of enormous value in manufacturing countless parts where it is necessary or desirable to machine the part after it has been sintered, such as is frequently the case with gears, rotors and sprockets. In the practice of this invention, calcium aluminoferrite powder can also be incorporated into parts which will not necessarily be machined for the sole purpose of attaining better corrosion resistance. Surprisingly, the incorporation of the calcium aluminoferrite powder into such parts does not significantly compromise the strength, durability, or wear characteristics of the part and generally improves the service life of the part by providing better corrosion resistance.

A sintered R-T-B based magnet includes a main phase formed of an R.sub.2T.sub.14B compound and a grain boundary phase at grain boundaries of the main phase. The grain boundary phase contains an R-T-M compound (M is at least one selected from the group consisting of Ga, Cu, Zn, Al and Si) and an R-M compound. In any cross-section of the sintered R-T-B based magnet, a sum of an area ratio of the R-T-M compound and an area ratio of the R-M compound is not lower than 1.5% and not higher than 3.5%, the area ratio of the R-T-M compound is not lower than 0.4% and not higher than 2.5%, and the area ratio of the R-M compound is not lower than 0.4% and not higher than 2.5%.