It has been found that metal parts having rough surfaces can be manufactured by (1) compacting a metal powder under high pressure in a mold to make a green part, wherein at least one face of the mold is roughened by electrical discharge machining to have an R.sub.a of 10 to 200 micro-inches, as measured with a profilometer having a stylus tip, (2) heating the green metal part to a temperature of at least 1500 F. to sinter the green metal part to produce the metal part having at least one rough surface, wherein the rough surface has an R.sub.a which is within the range of 10 to 200 micro-inches, as measured with a profilometer having a chisel tip, and (3) optionally, buffing, classifying, deburring and/or washing the metal part. This method can be beneficially used in manufacturing clutch plates, pressure plates, and cam shaft sprockets.

The invention relates to a method for calibrating, in particular, sintered pressed parts, wherein a calibration procedure of each individual pressed part is controlled depending on at least one specific pressed part parameter of the respective pressed part measured before calibration and/or depending on at least one production parameter of a preceding pressing and/or sintering step of the respective pressed part.

A calibration method includes positioning the coating unit in a first measuring position and detecting a first position reference value with respect to the reference point and a first measuring point associated with the coating unit at the first measuring position, positioning the coating unit in a second measuring position by moving the coating unit in the direction of movement and detecting a second position reference value with respect to the reference point and a second measuring point associated with the coating unit at the second measuring position, and determining a correction value for the first application element and/or the second application element from the detected first position reference value and the detected second position reference value.

A method of sizing a cavity in a part and a part made from such method. The method includes forming the part having the cavity, including forming a plurality of protrusions extending within the cavity from at least one internal surface of the cavity, the protrusions having distal ends bordering an unobstructed portion of the cavity, the unobstructed portion having an initial dimension at least partially defined by a position of the distal ends, pressing a deforming element against the distal ends of the protrusions to plastically deform the protrusions toward the at least one internal surface of the cavity and increase the initial dimension to a final dimension, and disengaging the deforming element from the distal ends.

A method for manufacturing an aluminium mould (1) segment (10) for curing and vulcanizing a tyre: a) fixing at least one thin blade (2) for the formation of the grooves in the tire tread, in a mould form made of friable material, so that an exterior part of the thin blade is embedded in the material of the mould form and so that an interior part projects from this mould form, this thin blade being made from maraging steel and having been obtained by a selective laser melting method, b) closing the mould form and pouring or injecting aluminium into it, coating the interior part of the thin blade, c) breaking away the mould form to obtain the mould segment. The thin blade (2) is subjected to a peening treatment with a material with a Vickers hardness between 340 and 500 HV and with dimensions smaller than 0.3 mm.

A method for manufacturing an aluminium mould (1) segment (10) for curing and vulcanizing a tyre: a) fixing at least one thin blade (2) for the formation of the grooves in the tire tread, in a mould form made of friable material, so that an exterior part of the thin blade is embedded in the material of the mould form and so that an interior part projects from this mould form, this thin blade being made from maraging steel and having been obtained by a selective laser melting method, b) closing the mould form and pouring or injecting aluminium into it, coating the interior part of the thin blade, c) breaking away the mould form to obtain the mould segment. The thin blade (2) is subjected to a peening treatment with a material with a Vickers hardness between 340 and 500 HV and with dimensions smaller than 0.3 mm.

The invention relates to additive manufacturing field and laser shock peening (LSP) field, in particular to a combined apparatus for layer-by-layer interactive additive manufacturing with laser thermal/mechanical effects. In the apparatus, a LSP module and a SLM module operate in alternate so as to perform LSP for the formed part in the forming process of the formed part, and thereby a better strengthening effect of the formed part is achieved. The invention effectively overcomes the challenges of shape control against deformation and cracking of the formed parts incurred by internal stress and property control against poor fatigue property of the formed parts incurred by metallurgical defects during additive manufacturing, improves fatigue strength and mechanical properties of the faulted parts, and realizes high-efficiency and high-quality holistic processing of the formed parts.

A sliding member (1) is formed of a sintered compact. The sintered compact includes: a base layer (3), which mainly contains an Fe-based structure and further contains 1.0 wt % to 5.0 wt % of Cu, a metal having a melting point lower than a melting point of Cu, and C; and a sliding layer (2), which is sintered together with the base layer (3) in a state of being held in contact with the base layer (3) and has a sliding surface (A). The sliding layer (2) mainly contains an Fe-based structure containing at least one kind of alloy element selected from Ni, Mo, Mn, and Cr and further contains Cu and C, and the content of Cu in the sliding layer (2) is larger than the content of Cu in the base layer.

The present invention relates to additive manufacturing field and laser shock peening (LSP) field, in particular to a combined apparatus for layer-by-layer interactive additive manufacturing with laser thermal/mechanical effects. In the apparatus, a LSP module and a SLM module operate in alternate so as to perform LSP for the formed part in the forming process of the formed part, and thereby a better strengthening effect of the formed part is achieved. The present invention effectively overcomes the challenges of shape control against deformation and cracking of the formed parts incurred by internal stress and property control against poor fatigue property of the formed parts incurred by metallurgical defects during additive manufacturing, improves fatigue strength and mechanical properties of the formed parts, and realizes high-efficiency and high-quality holistic processing of the formed parts.

In a die for compressing and sizing a sintered body at straight portions, upper taper portions are provided on a die upper portion and a core rod upper portion, and the straight portions are provided at a die lower portion and a core rod lower portion. The die upper portion and the core rod upper portion have Young's moduli higher than the die lower portion and the core rod lower portion. The die upper portion and the core rod upper portion are made of materials having Young's moduli that are at least 50 GPa higher than that of the sintered body. The sintered body can be densified with a smaller ironing margin. Since the sintered body is ironed without being compressed, by the upper taper portions and the core rod upper portion having high Young's moduli, the die is prevented from breaking and being abraded due to ironing.