Embodiments of the present disclosure provide improved techniques for creating SMA materials and SMA powders. SMA materials and powders formed may be used to form porous structures suitable for applications such as biomaterials, damping applications, actuators, and/or sensors. Embodiments for performing hydriding and dehydriding of SMA wires at low pressure and low temperature are provided. Methods may be used to produce a shape memory alloy (SMA) powder. Such methods may include hydriding a length SMA wire under low pressure for a period of time to produce a length of hydrided SMA wire, crushing the length of hydrided SMA wire to form a hydrided SMA powder, and dehydriding the hydrided SMA powder to form a dehydrided SMA powder.

It has been found that duplex monolithic parts can be manufactured in high volume at low cost by using powder metal technology to mold and sinter an inner component of the part into an outer component of the part. This technique reduces the cost of manufacturing intricate metal products by taking advantage of the attributes of powder metal technology in making the inner component of the part. The outer component of the part can be wrought machined, stamped or forged, or made by double press double sinter or forging a powder metal component of the part. In any case, this technique can beneficially be used in making a wide variety of toroid parts, such as gears, clutches, sprags, bearing races, one-way diodes, and the like.

An actuator includes a first ball-ramp plate, a second ball-ramp plate, and a plurality of balls. The first ball-ramp plate is formed of compressed powdered metal with ramps having a higher density than at least part of a remainder of the ball-ramp component. A method of manufacturing the actuator includes compacting a metal powder to form a blank of the first ball-ramp plate including an annular body disposed about an axis and a plurality of ramps fixedly coupled to the annular body and spaced circumferentially about the axis, and locally densifying the ramps of the blank by applying force to a ramped surface of each ramp.

A sintered gear of annular shape which has a composition including a metal, has a plurality of pores in a surface thereof, and has a relative density of 93% or more and 99.5% or less.

A helical sector gear having a body and a gear segment having a plurality of helical teeth. The gear segment has a toothed sector, on which all of the helical teeth are formed, and spacing segments on the opposite circumferential ends of the toothed sector. Each of the spacing segments has a circumferential surface, which is longer than a pitch of the helical teeth, and a radial surface that is formed in a helical manner that conforms to the helix angle of helical teeth. A die set for forming the helical sector gear and a related method are also provided.

A method for manufacturing a high-torque hexagonal drill shank includes: firstly producing an air module, wherein the lower end of the air module is inserted into a molding cavity of a mold, a high-pressure air is injected into the air module, and the surface of the air module is provided with a plurality of air outlets; evenly mixing metal powder and an organic binder together; injecting obtained particulates in a heating-plasticizing state into the molding cavity by an injection molding machine to solidify and form a hexagonal drill shank blank; forming a non-cylindrical cavity inside the hexagonal drill shank blank under the action of the air module; removing the binder in the hexagonal drill shank blank by thermal decomposition; and, finally, obtaining a high-torque hexagonal drill shank by sintering and densifying.

A sintered gear of annular shape which has a composition including a metal, has a plurality of pores in a surface thereof, and has a relative density of 93% or more and 99.5% or less.

A device for producing a gear green compact from a powder includes a die, an upper stamp, and a lower stamp, wherein the die has at least one helical toothing on an inner lateral surface, which helical toothing extends only over a partial area of the circumference of the inner lateral surface, and which has a first helix angle, wherein, adjoining the first helical toothing in a circumferential direction, one toothed edge surface is formed on each side, both of which have a second helix angle, wherein at least one of the second helix angles of the die is unequal to the first helix angle of the helical toothing of the die.

A sintered material with a composition composed of an iron-based alloy and a structure in which the number of compound particles 0.3 μm or more in size is less than 200 per 100 μm×100 μm unit area in a cross section, wherein the sintered material has a relative density of 93% or more.

This application relates to a method of manufacturing a cooling pipe for a powertrain of an electric vehicle. The method may include preparing a powdered composite material by ball-milling aluminum alloy particles and carbon nanotube particles. The method may also include preparing a multilayer billet containing the powdered composite material and comprising a core layer and two or more shell layers surrounding the core layer. The method may further include extruding the multilayer billet to produce a pipe-shaped extrusion. The core layer is made of the powdered composite material or an aluminum alloy, the outermost shell layer of the two or more shell layers is made of an aluminum alloy, and the remaining shell layers are made of an aluminum alloy. This application also relates to a cooling pipe manufactured by the method, an electric vehicle motor and an electric vehicle battery pack casing including the cooling pipe.