Challenge: To develop a proof of concept showing the advantages of converting an existing conventional metal carrier design to Powder Metal.

Solution: Carriers must be lightweight, yet strong enough to endure the twisting load of four-wheel-drive transfer case. To ensure that the alignment of transfer case gears does not shift, carriers must be manufactured from high strength materials. Metaldyne, together with its customer, developed several analytical techniques to test whether or not a carrier manufactured from Powder Metal could withstand the physical loads required in daily automotive use. Several prototypes were also manufactured and placed into vehicles for real world testing.

Result: The Powder Metal carrier successfully passed all tests. In addition, its lighter weight together with the inherent ability of the Powder Metal process to create complex shapes more easily than conventional metalworking demonstrated advantages not before realized by the customer. The success of the program has resulted in further research with the customer to identify other components that can benefit from the inherent advantages of Powder Metal.