Manufacture of rotors and shafts by powder metallurgy technology
Eurobalt Production Success
Series of rotors and shafts manufactured using powder metallurgy
Eurobalt has successfully completed the delivery of a pilot-industrial batch of rotors and shafts for a major European manufacturer of special equipment. The key to success was powder metallurgy (PM) with subsequent sintering — a technology that opens new horizons for precision, strength and cost-effectiveness in modern mechanical engineering.
Production Results Demonstration
Advantages of Powder Metallurgy
🔧 Minimal Waste
The product is formed almost to the final contour, reducing metal losses to 3-5% compared to conventional processing methods.
📏 High Precision
Achievable accuracy IT8-IT9 directly after sintering, minimizing the need for mechanical finishing.
⚡ Controlled Properties
Selection of powder composition allows obtaining required hardness, wear resistance and corrosion resistance.
💰 Economic Efficiency
For medium and large series, savings reach 30-40% of total production costs.
Manufacturing Process
Powder Mix Preparation
Using alloy steels with particle size less than 80 microns and adding 0.6% lubricant to ensure optimal flowability.
Cold Pressing
Forming blanks under pressure 400-600 MPa achieving density of 6.5-6.8 g/cm³.
High-Temperature Sintering
Processing at temperature 1120-1150°C in controlled N₂-H₂ atmosphere for 60-90 minutes.
Calibration and Finishing
Re-pressing to improve accuracy and machining of critical surfaces to Ra ≤0.8 μm.
Technical Specifications
| Parameter | Value | Note |
|---|---|---|
| Material | Sintered steel with 2% nickel content | Enhanced strength and toughness |
| Density | 6.9-7.0 g/cm³ | 95-97% of theoretical density |
| Hardness | 25-30 HRC | Optimal for most applications |
| Manufacturing accuracy | IT8-IT9 | Achievable directly after sintering |
| Surface roughness | Ra 2.5-3.2 μm | After sintering, before finishing |
| Maximum diameter | Up to 120 mm | Limitation for complex parts |
Achieved Results
📈 Cost Reduction
- Material waste reduction by 40-50%
- Labor cost reduction by 30-40%
- Energy consumption reduction by 20-25%
⚙️ Operational Improvements
- Vibration reduction by 10-15%
- Service life increase by 15-20%
- Energy efficiency improvement by 3-5%
⏱️ Delivery Cycle Reduction
Full production cycle reduced to 6 weeks versus 12 weeks for conventional forging with machining.
🌱 Environmental Impact
For each ton of production, up to 400 kWh of energy and 150 kg CO₂ equivalent are saved.
Technology Applications
Powder metallurgy is optimal for:
- Complex geometry — internal keyways, oil channels, variable cross-sections
- Series production — from 1,000 units per year and higher
- High uniformity requirements — minimal variation in mechanical properties
- Combined materials — combination of steel and copper phases in one product
- Weight reduction — controlled porosity without strength loss
About Eurobalt Production Capabilities
Our company combines foundry, powder metallurgy and machining production within a single technological cluster in the Baltics. This allows us to provide a complete manufacturing cycle — from tooling design to finished product packaging.
🏭 Modern Equipment
Own fleet of presses with force up to 800 tons, horizontal sintering furnaces up to 1200°C
🔬 Quality Control
Metrology laboratory accredited to ISO 17025 standard
👥 Expertise
Team of engineers with over 15 years experience in powder metallurgy
📋 Flexibility
Capability to manufacture both prototypes and large series up to 500,000 parts per year
Ready to discuss your project?
Contact our engineers and learn how Eurobalt powder metallurgy technologies will help reduce costs and improve reliability of your rotors, shafts and other rotating parts.
📧 info@eurobalt.net | 🌐 www.eurobalt.net
We will respond within 24 hours
