High density forming process with powder blends

A method of forming sintered powder metal articles by:

• (a) selecting a target critical diameter so as to achieve through hardening upon quenching of the formed sintered article;
• (b) selecting a powder composition which achieves the selected target critical diameter;
• (c) blending said powder composition;
• (d) pressing said blended mixture to form said article;
• (e) sintering said compact at a temperature of at least 1100.degree. C.;
• (f) forming said sintered article in a closed die cavity having a clearance so as to produce a formed sintered powder metal part having a compressed length which is approximately 3 to 19% less than the original length when subjected to a pressure between 40 and 90 tonnes per square inch so as to increase the density of said formed sintered article.

A method of producing a sintered powder metal article comprising:

• (a) selecting a target critical diameter so as to achieve through hardening upon quenching of the formed sintered article;
• (b) selecting:
• (i) a powder composition so as to achieve said selected critical target diameter;
• (ii) a pressure to form said sintered powder metal article at a density of 7.4 to 7.7 g/cc;
• (iii) a forming tool so as to provide a clearance in said tool for movement of said formed sintered article to final shape with increased density to said 7.4 to 7.7 g/cc.