Toyota has succeeded in cutting material losses to 0.05 percent when producing powder metal (PM) synchromesh clutch hubs in gearboxes.

The automaker wanted the final product to have a better surface finish, to reduce post-processing as much as possible, and thus cut waste. This required components being pressed with less variation in final dimensions and with minimal weight differences between units

Toyota sought a solution involving powder metallurgy from Höganäs. Its response to this challenge was to bind agents and process powder during pressing. The concept was based on a new mixing concept, Starmix Boost, a zinc-free, press-ready bonded mix designed to meet all metal powder performance criteria.

The new powder mix has resulted in a new synchromesh clutch hub that was significantly stable in terms of density and weight. Waste was reduced, and the otherwise frequent adjustment of press settings was eliminated, saving time. Material losses have been reduced to 1/20th of traditional methods and materials. Thus, a reduction in post-processing operations has been achieved.

This collaboration has benefited both parties. Toyota has been able to take another step toward its vision of zero materials losses, while Höganäs has pushed the limits of powder metallurgy further.

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