Atlas Pressed Metals was tasked with producing a series of parts that balanced geometric complexity, tight tolerances, and material strength – all while meeting strict cost and cleanliness requirements.

Each part presented unique challenges:

• Automotive compound gear: Required precise gear forms with AGMA Class 7 accuracy and minimal distortion.
  
  
• Appliance cam: Needed to handle a heavier, redesigned appliance lid while maintaining balanced density and reducing costs.
  
  
• Cylindrical housing: Included intricate interior vein and exterior rib features that were not economically feasible with traditional machining or EDM methods.
  
  

Traditional processes such as machining, welding, or secondary heat treatment would have added significan

Atlas applied sinter hardening to each of these components – an in-furnace quench-hardening process that eliminates the need for secondary heat treatment and ensures dimensional stability.

• Automotive compound gear: The sinter-hardening process produced complex gear geometry that maintained total composite error within AGMA Class 7 limits. The approach also reduced distortion compared to conventional oil quenching.
  

• Appliance cam: Using multi-level compaction, Atlas produced a net-shape cam component that required no post-processing other than plating. By switching from an iron-copper alloy (50 ksi yield strength) to a sinter-hardened iron-chromium prealloy (120 ksi yield strength), Atlas met new load requirements and reduced part cost by 66%.
  
  
• Cylindrical housing:  For this small housing with intricate internal veins, Atlas used a sinter-hardened material blended with a proprietary lubricant to maintain density and integrity throughout compaction and ejection. The result was a dimensionally stable part with clean surfaces, requiring no secondary heat treatment.

Atlas applied sinter hardening to each of these components – an in-furnace quench-hardening process that eliminates the need for secondary heat treatment and ensures dimensional stability.

Automotive Gear

The sinter-hardening process produced complex gear geometry that maintained total composite error within AGMA Class 7 limits. The approach also reduced distortion compared to conventional oil quenching.

Appliance Cam

Using multi-level compaction, Atlas produced a net-shape cam component that required no post-processing other than plating. By switching from an iron-copper alloy (50 ksi yield strength) to a sinter-hardened iron-chromium prealloy (120 ksi yield strength), Atlas met new load requirements and reduced part cost by 66%.

Cylindrical Housing

For this small housing with intricate internal veins, Atlas used a sinter-hardened material blended with a proprietary lubricant to maintain density and integrity throughout compaction and ejection. The result was a dimensionally stable part with clean surfaces, requiring no secondary heat treatment.