World-Class Powder Metal Parts
1049 Owens Road, Jamestown, TN 38556
931-879-9946
 

Case Studies

High-density, structural parts are
the hallmark of Micro Metals.
We are experienced in a wide range of ferrous and nonferrous materials, including copper and nickel alloys of iron, pre-alloyed material, stainless steels and many grades of brass and bronze. With our extensive capabilities in machining, heat treating and finishing, we are able to support our customers with unsurpassed satisfaction, producing the most complex parts.

Featured Case Studies

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Case Studies
Automotive
  • Material: FN-0208
  • Heat treated & tempered to HRC 55
  • UTS – 120,000 PSI
  • Designed for the P/M process
Case Studies
Automotive
  • Material: FN-0208
  • Heat treated & tempered to HRC 57 particle hardness
  • UTS – 120,000 PSI
  • Designed for the P/M process
Case Studies
Automotive
  • Material: FN-0200
  • Heat treated & tempered to HRC 55 particle hardness
  • UTS – 120,000 PSI
  • Design converted from machined bar stock for 50% savings
Case Studies
Automotive
  • Material: FLC-4608
  • Sinter hardening to HRC 55 particle hardness
  • UTS – 85,000 PSI
  • Designed for the P/M process
Case Studies
Automotive
  • Material: FLC2-4808
  • Sinter hardening to HRC 55 particle hardness
  • UTS – 145,000 PSI
  • Design converted from machined forging to P/M for cost savings of $4.50/part
Case Studies
Automotive
  • Material: FN-0208
  • Heat treated & tempered to HRC 57 particle hardness
  • UTS – 120,000 PSI
  • Design converted from machined casting for 35% savings.
Case Studies
Automotive
  • Material: FN-0208
  • Heat treated & tempered to HRC 57 particle hardness
  • UTS – 120,000 PSI
  • Design converted from machined casting for 35% savings.
Case Studies
Automotive
  • Material: FN-0208
  • Heat treated & tempered to HRC 57 particle hardness
  • UTS – 120,000 PSI
  • Designed for the P/M process
Case Studies
Automotive
  • Material: FX-1008 (copper infiltrated)
  • Sintered to HRB 89 particle hardness
  • UTS – 87,000 PSI
  • Design converted from machined casting for 35% savings
Case Studies
Automotive
Synchronizer Hub
Transfer case for 4-wheel drive SUVs
External and internal involute spline
  • Material: Sinter-hardened steel
  • MPIF FLC-4708
  • Density: 6.70 gm/cm3 min.
  • Heat treat: Sinter hardened to HRc 32 min. apparent hardness
  • General tolerances held: MOW of 0.0052" total
  • MBW of 0.004"
  • Thickness to ±0.004"
  • Geometric tolerances held: Face perpendicular to internal spline within 0.004'
  • Runout of O.D. pitch dia. to I.D. pitch dia. within 0.006'
Case Studies
Automotive
Spacer Lever
Transfer case for 4-wheel drive SUVs
  • Material: 80/20 brass MPFI CZ-2000-11
  • Density: 7.6 gm/cm3 min.
  • General tolerances held: ±0.25 min.
Case Studies
Automotive
Finger - Shift Selector
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1005-110HT
  • Density: 7.3 gm/cm3 min.
  • Secondary machining: Drill side hole and countersink
  • Mill angles on side tab
  • Bore I.D.
  • Mill face
  • Heat Treat:
  • Harden and temper to:
  • Apparent hardness: HRc 33 min.
  • Particle hardness: HRc 50-58
  • General tolerances held: ±0.0015" flange thickness
  • 0.004" total O.D.
  • 0.0023" total I.D.
  • Geometric tolerances held: Cross hole to I.D. position within Ø 0.004
  • Finishes: 2.0 micrometer Ra
Case Studies
Automotive
Lug - Fifth/Reverse
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1005-110HT
  • Density: 7.3 gm/cm3 min.
  • Secondary machining: Drill side hole and countersink
  • Mill slot with angles
  • Heat treat:
  • Harden and temper to:
  • Apparent hardness: HRc 33 min.
  • Particle hardness: HRc 50-58
  • General tolerances held: ±0.004"; 0.004" total for I.D. and side slot
  • Geometric tolerances held: Cross hole to side slot true position within Ø 0.004"
  • Side slot perpendicular to I.D. within 0.006"
  • Finishes: 1.6 micrometer Ra
Case Studies
Automotive
Lug - Shift Selector
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1005-110HT
  • Density: 7.3 gm/cm3 min.
  • Secondary machining: Drill side hole and countersink
  • Mill side slot
  • Bore I.D.
  • Mill face
  • Heat treat:
  • Harden and temper to:
  • Apparent hardness: HRc 33 min.
  • Particle hardness: HRc 50-59
  • General tolerances held: 0.0024" total I.D.
  • 0.004" total for O.D.
  • 0.0008" total cross hole
  • 0.004 total slot width
  • Geometric tolerances held: Face perpendicular to I.D. within 0.002"
  • Finishes: 2.0 micrometer Ra
Case Studies
Automotive
Socket - Shift Shaft
Transmission
  • Material: Iron/copper infiltration
  • FX-1008
  • Density: 7.10 gm/cc min.
  • Sintered: Apparent hardness Rockwell "B" 70 min.
  • General tolerances held: ± 0.254 mm
  • Closest tolerances held: Through hole ±0.050 mm
  • Counterbore hole ±0.025 mm
  • Side hole ±0.015 mm
  • Geometric tolerances held: Position Ø 0.050 mm
  • Straightness Ø 0.008 mm
  • Finishes: All finishes 6.3 micrometers
Case Studies
Automotive
Link 5/R
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1005-110HT
  • Secondary machining: Drill side hole & countersink
  • Mill face
  • Density: 7.3 gm/cm3 min.
  • Heat treat:
  • Harden and temper to:
  • Apparent hardness: HRc 33 min.
  • Particle hardness: HRc 50-58
  • General tolerances held: ±0.004"
  • 0.004" total for I.D.
  • 0.0024" total for slot width
  • 0.004 total for thickness
  • Geometric tolerances held: Face perpendicular to I.D. within 0.0025"
  • Cross hole position to I.D. within Ø 0.006"
  • Finishes: 2.0 micrometer Ra
Case Studies
Automotive
Blocker - Shift Interlock
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1005-110HT
  • Density: 7.3 g/cm3 min.
  • Secondary machining: Drill side holes
  • Mill side slot and thru slot
  • Bore I.D.
  • Mill angles and large face
  • Heat treat:
  • Harden and temper to:
  • Apparent hardness: HRc 33 min.
  • Particle hardness: 50-58
  • General tolerances held: Flange thickness/slot width ±0.0028"
  • 0.004" total I.D.
  • Geometric tolerances held: Flange faces perpendicular to I.D. within 0.002"
  • True position within 0.0024"
  • Finishes: 1.6 micrometers Ra
Case Studies
Automotive
Thrust Washer
Transmission
  • Material: Iron/copper
  • FX 20008-90HT or FL 4205 120HT
  • Density: 7.00 gm/cc min.
  • Heat treat: Apparent hardness 35 HRc min.
  • Matrix hardness 53-62 HRc
  • General tolerances held: ±0.150 mm
  • Closest tolerances held: Outside radius ±0.180 mm
  • Radial thickness ±0.112 mm
  • Overall thickness ±0.020 mm
  • Geometric tolerances held: Flatness 0.020 mm
  • Parallelism 0.020 mm
  • Position 0.100 mm
  • Finishes: General surfaces 1.6 micrometers Ra
  • Top and bottom surfaces 0.8 micrometers Ra
Case Studies
Automotive
Segment - Idler Shaft Support
Transmission
  • Material: Copper steel
  • FE 93.5-98.2%; CU 1.5-3.9%; C 0.3-0.6%; Others 2.0% max
  • Density: 6.30 gm/cc
  • Heat treat: Heat treat and temper to a mill file hard to Rockwell C60 file
  • General tolerances held: ±0.254 mm
  • Closest tolerances held: Overall thickness ±0.254 mm
  • Outside radius ±0.038 mm
  • Inside diameter ±0.023 mm
  • Geometric tolerances held: Position Ø 0.100 mm
  • Perpendicularity 0.100 mm
  • Strength: Yield 35 KSI (tensile bar)
  • Tensile 40 KSI
Case Studies
Automotive
Link Assembly Input Rail
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1008-50
  • Density: 7.2 gm/cm3 min.
  • Secondary operations: Bore large diameter hole
  • Ream small diameter hole
  • Machine large slot
  • General tolerances held: ±0.25
  • Closest tolerances held: Large hole: 0.03 mm total
  • Small hole: 0.02 mm total
  • Slot width: 0.08 mm total
  • Geometric tolerances held: Position 0.08 MMC
  • Slot perpendicular to small hole within 0.05 mm
Case Studies
Automotive
Bar Support
Transmission
  • Material: Nickel steel
  • MPIF FN-0208
  • Density: 6.9-7.2 bm/cm3
  • Heat treat: Thru harden and temper
  • General tolerances held: ±0.01"
  • Geometric tolerances held: Parallel 0.004"
Case Studies
Automotive
Arm Lever
Manual transmission
  • Material: Copper steel
  • MPIF FC-0208-50
  • Density: 7.0 gm/cm3 min.
  • Secondary machining: Both through holes
  • General tolerances held: ±0.25 mm
  • Closest tolerances held: Thru hole 0.03 mm total
  • Geometric tolerances held: Position Ø 0.15 RFS
Case Studies
Automotive
Link Primary Rail
Manual transmission
  • Material: Copper-infiltrated steel
  • MPIF FX-1008-50
  • Density: 7.28/cm3 min.
  • Heat treat: Induction harden and temper flange to HRc 50 min.
  • Case depth 2.0-5.0 mm
  • General tolerances held: Flange thickness: 0.08 mm
  • I.D.: 0.03 mm
  • Slotwidth: 0.07 m
  • Geometric tolerances held: Flange faces perpendicular to I.D. within 0.05 mm
  • Slot true position to I.D. 0.03 mmc
  • Finish: 1.6 micrometers Ra
Case Studies
Automotive
Drive Gear
Power sunroof
  • Material: Distaloy 4800A
  • MPIF FD-4805
  • Density: 6.70 gm/cc min.
  • Heat treat: Harden and temper to a micro hardness of Rc 50-60
  • General tolerances held: 0.005" total
  • Geometric tolerances held: Runouts of O.D. to gear O.D. within 0.0028" max.
Case Studies
Automotive
Ten-Tooth Pinion — Two-Piece Assembly
Power window motor assembly
  • Material:
  • Base: FN-0208
  • Pinion: FC-0208
  • Density:
  • Base: 6.8 gm/cm3 min.
  • Pinion: 7.0 gm/cm3 min.
  • Heat treat: Harden and temper to apparent HRc 30 min.
  • General tolerances held: ±0.004" thickness dimension
  • ±0.002" diametral dimension
  • Geometric tolerances held: Pinion O.D. concentric to I.D. within 0.004" total
  • Finishes: 0.8 micrometer (I.D.)
Case Studies
Automotive
Wiper
Fuel injection control mechanism
  • Material: Copper steel
  • FC-02-5-S
  • Density: 6.80/7.40 gm/cc
  • General tolerances held: ±0.25 mm
  • Closest tolerances held: Inside radius ±0.13 mm
  • Outside radius ±0.13 mm
  • Inside diameter ±0.04 mm
  • Coating: Both sides color coded with Dykem stain
Case Studies
Automotive
Balance Weight
Air compressor
  • Material: Copper steel
  • Cu 1.5-3.9%; C 0.6-0.9%; Others 2.0% max; Fe remainder
  • Density: 6.50-6.80 gm/cc
  • General tolerances held: ±0.30 mm
  • Closest tolerances held: Counterbore depth ±0.20 mm
  • Thickness ±0.20 mm
  • Hole diameter s0.07 mm
  • Center-to-center distance ±0.05 mm
  • Tapered hole ±0º 12' mm
  • Geometric tolerances held: Concentricity Ø 0.05
  • Parallelism of I.D. centerlines 0.05
Case Studies
Automotive
Cam
Armrest adjustment
  • Material: Nickel steel
  • MPIF FN-0405-130HT
  • Density: 6.8 gm/cm3 min.
  • Heat treat: Apparent hardness HRc 31 min.
  • General tolerances held: ±0.010"
  • Geometric tolerances held: Flatness within 0010
Case Studies
Automotive
Pawl
Armrest adjustment
  • Material: Nickel steel
  • MPIF FN-0405-130-HT
  • Density: 6.8 gm/cm3 min.
  • Heat treat: Apparent hardness HRc 31 min.
  • General tolerances held: ±0.005"
Case Studies
Automotive
Gear
Armrest adjustment
  • Material: Nickel steel
  • MPIF FN-0405-130HT
  • Density: 6.8 gm/cm3 min.
  • Heat treat: Apparent hardness HRc 31 min.
  • General tolerances held: ±0.005"
Case Studies
Lawn & Garden
Blade Adapter
42/48" lawn mower blade adapter
  • Material: Iron/copper steel
  • MPIF FC-0208-50
  • Density: 6.70 gm/cm3+ min.
  • Heat treat: N/A
  • General tolerances held: ±0.006"
  • Geometric tolerances held: Parallel within 0.005"
Case Studies
Lawn & Garden
Washer
42/48" lawn mower
  • Material: MPIF F0000
  • Density: 6.4 gm/cm3
  • General tolerances held: ±0.1 mm
  • Thickness: 1.25 mm
Case Studies
Lawn & Garden
Arm
42/48" lawn mower
  • Material: Copper steel MPIF FX-0208-50
  • Density: 6.7 gm/cm3 min.
  • General tolerances held: ±0.25 mm
  • Closest tolerances held:
  • I.D.: ±0.08 mm
  • Geometric tolerances held: Position Ø 0.3 MMC
Case Studies
Lawn & Garden
Bushing - Seat Adjust
42/48" lawn mower
  • Material: Copper steel
  • MPIF FC-0208-50
  • Density: 6.7 gm/cm3 min.
  • General tolerances held: ±0.1
Case Studies
Lawn & Garden
Latch
42/48" lawn mower
  • Material: Copper steel
  • MPIF FC-0208-50
  • Density: 6.7 gm/cm3 min.
  • General tolerances held: ±0.15 mm
  • Geometric tolerances held: Hub depth: ±0.15 mm
  • Hexagon: ±0.25 mm
Case Studies
Automotive
Lockout Mechanism
Rear differential
  • Material: Copper steel
  • FC-0208
  • Density: 6.60 g/cc (min)
  • Heat treat: Heat treat and temper to an apparent hardness of Rc 35-50
  • General tolerances held: ±0.25 mm
  • Closest tolerance held: Position of outer radius ±0.13 mm
  • Undercut heights ±0.13 mm
  • Thru hole ±0.05 mm
  • Geometric tolerances held: Parallelism 0.20 mm
  • Position Ø 0.08 mm
  • Magnetism: 15 GAUSS max
Case Studies
Automotive
Block - Reaction
Rear differential
  • Material: Copper steel
  • ES-14008 or FN-0208
  • Density: 6.80 g/cc (min)
  • Heat treatment: Harden and temper to an apparent hardness of Rc 35-50
  • General tolerances held: ±0.25 mm
  • Closest tolerances held: Thickness ±0.19 mm
  • Width between flats inside hole ±0.13 mm
  • Outside diameter ±0.05 mm
  • Geometric tolerances held: Parallelism 0.25 mm
  • Flatness 0.13 mm
  • Position 0.13 mm
  • Magnetism: 15 GAUSS max
Case Studies
Automotive
Counterweight
Rear differential
  • Material: Copper steel
  • FC-0205-R or ES-140009
  • Density: 6.40-6.80 g/cc
  • Sintered: Apparent hardness of Rb 50-95
  • General tolerances held: ±0.13 mm
  • Closest tolerances held: Corner radii ±0.20 mm
  • Undercut heights ±0.06 mm
  • Thru hole ±0.06 mm
  • Geometric tolerances held: Position 0.06 mm
  • Magnetism: 15 GAUSS max
Case Studies
Automotive
Rack Stopper
Rack and pinion steering
  • Material: Copper steel
  • Cu 1-3%; C 0.6-0.9%; Others 2.0% max; Fe remainder
  • Density: 6.80-7.20 g/cc
  • Sintered: Apparent hardness of Rb 40-85
  • General tolerances held: ±0.20 mm
  • Closest tolerances held: Groove diameter ±0.05 mm
  • Side hole diameter ±0.05 mm
  • Outside diameter ±0.04 mm
  • Groove radius ±0.35 mm
  • Geometric tolerances held: Concentricity Ø 0.05 mm
  • Perpendicularity 0.10 mm
  • Position 0.20 mm
  • Strength: Tensile 35-60 Kgf/mm2
Case Studies
Appliance
Counterweight
Air conditioning unit compressor
  • Material: 80/20 sintered brass
  • MPIF CT-1000
  • Density: 7.8 gm/cc (min)
  • General tolerances held: ±0.13 mm
  • Closest tolerances held: Inside radius ±0.06 mm
  • Outside radius ±0.06 mm
  • Slot distance ±0.03 mm
Case Studies
Appliance
Socket
Blender drive connector
  • Material: Stainless steel
  • SS-410-R
  • Density: 6.60 gm/cc (min)
  • Heat treat: Apparent hardness of Rc 25 min.
  • General tolerances held: ±0.13 mm
  • Closest tolerances held: Counterbore hole ±0.04 mm
  • Width between flats of star form ±0.04 mm
  • Geometric tolerances held: Concentricity ±0.03 mm
Case Studies
Appliance
Thrust Plate
Compressor
  • Material: Copper steel
  • Density: 6.00-6.40 gm/cc
  • General tolerances held: ±0.25 mm
  • Closest tolerances held: Thickness ±0.13 mm
  • Hole diameter ±0.13 mm
  • Cavity depth ±0.13 mm
  • Center-to-center ±0.10 mm
  • Cavity width ±0.10 mm
  • Geometric tolerances held: Flatness ±0.06 mm
Case Studies
Appliance
Coupling
Home appliance
  • Material: FC-0208 @ 6.6 gms/cc minimum density, resin impregnated and zinc plated
  • MPIF SS-410L
  • Density: 6.40 gm/cm3 min.
  • General tolerances held: ±0.005"
  • Closest tolerances held: Thru hole ±0.002"
  • Geometric tolerances held: Concentricity within 0.004"
Case Studies
Power Tool
Gear - Spur
Hammer drill
  • Material: Nickel steel
  • FN0208-180HT
  • Density: 7.20-7.40 gm/cc (including gear teeth)
  • Heat treat: Harden and temper to a micro hardness of Rc 50-55
  • General tolerances held: ±0.13 mm
  • Closest tolerances held: Tooth-to-tooth comp. tol ±0.04 mm
  • Ramp height ±0.05 mm
  • Tooth composite tol. ±0.08 m
Case Studies
Power Tool
Lever Depth Lock
Power tools
  • Material: Nickel steel
  • F-0008
  • Density: 6.80 gm/cc (min)
  • Heat treat: Hardness and temper to an apparent hardness of Rc 20 min.
  • General tolerances held: ±0.13 mm
  • Closest tolerances held: Counterbore diameter ±0.13 mm
  • Counterbore depth ±0.13 mm
  • Cam form ±0.08 mm
  • Through hole (I.D.) ±0.06 mm
  • Geometric tolerances held: Total runout ±0.089 mm
  • (O.D./counterbore
Case Studies
Power Tool
Fence Slide Guide
Power tools
  • Material: Copper steel
  • FC0208-95HT
  • Density: 6.90-7.30 gm/cc
  • Heat treat: Harden and temper to a Rockwell C hardness of 35-50
  • General tolerances held: ±0.13 mm
  • Closest tolerances held: Base width ±0.05 mm
  • Hub width ±0.05 mm
  • Hub diameter ±0.05 mm
Case Studies
Automotive
Nut Actuator Brake Shoe
Brake assembly (rear axle)
  • Material: Copper-infiltrated steel
  • FX-1008-T
  • Heat treatment: Hardened and tempered by the consumer after broaching of the I.D.
  • General tolerances held: ±0.40 mm
  • Closest tolerances held: Thickness ±0.20 mm
  • Major diameter external gear ±0.34 mm
  • Geometric tolerances held: Circular runout 0.10 mm
Case Studies
Electrical
Bushing
Conduit nut
  • Material: MPIF F-0000
  • Density: 6.80 gm/cm3 min.
  • General tolerances held: ±0.005"
Case Studies
Hydraulic Motor
Commutator Blank
Hydraulic motor
  • Material: Copper steel
  • MPIF FC-0208-50
  • Density: 6.7 gm/cm3 min.
  • General tolerances held: ±0.003"
  • Geometric tolerances held: Runout 0.006"
CERTIFIED
TS 16949
Location
Jamestown, Tennessee

Automotive Transmission-Transfer Case

Automotive Transmission-Manual

Segment - Idler Shaft Support
Application: Automotive - transmission

Automotive Drive-Train

Automotive Steering

Automotive Miscellaneous

Lawn & Garden

Bushing - Seat Adjust
Application: 42/48" lawn mower

Appliance

Powertool

Fence Slide Guide
Application: Power tools

Heavy Truck

Hardware

Hydraulic Motor