Designing and analyzing a rocker arm using Powder Metallurgy Forging (PMF) (KEY IJP************866)

• M.gunasekaran,L.periyannan,R.soundarajan

Abstract

This work investigates powder metallurgy forging rocker arm part as a new approach for near-net- shape processing of titanium alloys using a coarse particle size distribution (PSD) between 90 and 250 m. This route was utilised to takes advantage of power metallurgy forgings (PMFs) enclosed nature to make near-net-shape components with conventional forging equipment, making it attractive and viable even for reactive powder such as titanium. In this study, the uncompact Ti-6Al-4V ELI powder was sealed under vacuum in a stainless-steel canister and hot forged in air to produce a fully dense titanium femoral stem. After the final forging stage, the excess material in the flash region was cut, which efficiently released the canister, revealing the forged part with minimal surface contamination. The as-forged microstructure comprises coarse grains with a martensitic structure. The subsequent annealing was able to generate a fine and homogenous lamellar microstructure with mechanical properties that respects the surgical implant standard, showing that PMF offers significant potential for forged titanium parts. Therefore, the PMF process provides a suitable alternative to produce titanium rocker arm components using basic equipment, making it more available to the Automobile industry.