ASCO CELEBRATES 40 + YEARS OF AWARD WINNING INDUSTRY RECOGNITION
Winners of the 2012 Powder Metallurgy Design Excellence Awards Competition sponsored by the Metal Powder Industries Federation were announced at PowderMet2012. ASCO Sintering Co. received the Grand Prize in the Hardware/Appliances Category for a copper-infiltrated PM steel inside deadbolt chassis made for a new commercial electronic lock system made by Ingersoll Rand Security Technologies.
Made to a density of 7.4 g/cm3, the part has an ultimate tensile strength of 110,000 psi, 75,000 psi yield strength, and 100 ft·lbf unnotched Charpy impact strength. Maintaining the density between the hub and flange is especially critical. The part has two PM posts manufactured and installed while maintaining true position and square-ness. Secondary operations include adding the tapped posts, two slots on the shelf flange, two counter-bores, and a countersink. PM was selected over castings and stampings, which could not meet strength or Builders Hardware Manufacturers Association requirements for integrity during high-temperature tests. PM processing minimized the process steps required to 8 vs. 17 for alternative methods. Material-utilization for PM process vs. alternative methods for manufacturing this part are 95% vs. 45% respectively. Energy input is estimated at 0.32 kWh/piece for PM, and 0.61 kWh/piece for wrought/stamping, translating into 47% energy savings by using the PM process. Customer realized an overall 20% cost reduction for this part.
This Grand Prize again distinguishes ASCO Sintering as the company with the most design awards in competition history, beginning in 1969, and is another outstanding example of powder metallurgy's precision, performance, complexity, economy, and innovation.
Six Sigma Certifications
To further complement and enhance our internal best practices, ASCO Sintering Co. has recently completed the training and Green Belt Certification of an additional eight employees in the methods of Six Sigma. This brings the total number of employees having Green Belt Certification to 46% of the ASCO work force.
For a seventh consecutive year, two teams of USC engineering students completed a final year project at ASCO. The scope helps to provide a real world experience for the students, not only in industrial, mechanical and production engineering, but also an appreciation of operating costs such as workers compensation and medical premiums, electricity, and gas.