Selectively Densified Powder Metal Helical Gears While the weight and cost benefits of standard powder metal based processing techniques are attractive for helical transmission gears, the torque to be transmitted is limited due to the porous structure. GKN Automotive has developed a process for surface densification which allows accurate strengthening of defined areas of the gear. The process creates gear teeth with properties comparable to a traditionally forged part while crucially improving the NVH characteristics of the component. Benefits > Ability to transfer high torque loads > NVH improvements due to better damping behaviour > Manufacturing process allows more design freedom > Traditional weight and cost benefits of sinter process Case Study As vehicle manufacturers explore opportunities to lower vehicle weight with new materials such as CFRP, especially in eDrive applications the NVH sensitivity is increased. The application of a sintered and surface densified helical intermediate gear in an eDrive transmission matches the torque transfer performance of a traditional forged gear in even the high torque environment associated with this application. Improved are the NVH characteristics of the transmission, as well as opportunities of weight reduction and cost. Validation trials are ongoing and the extended use of PM technology will enable vehicle manufacturers to adopt lighter vehicle architectures that still deliver a refined driving experience. For further information please contact: GKN Sinter Metals Engineering Dahlienstraße 43, 42477 Radevormwald, Germany Tel: +49 2195 609 971 Email: gerd.kotthoff@gkn.com, www.gknsintermetals.com