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PRC (Porous Ring Carrier)

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MAHLE Valvetrain GmbH Zell i.W.
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PRC (Porous Ring Carrier)
Benefit: Cost Saving, Improved Performance
Main Forming Process: Conventional Processing
End Use Sector: Automotive
Material: Copper, Ferrous


The porous ring carrier was developed to replace a casting solution with a PM part. On the one hand for cost reasons, on the other hand due to mechanical and metallurgical requirements (keyword: clamping in the piston).

The porous ring carrier is an award winning part in recent competitions, because the PM part was developed that has an unconventional density (4.0 g/cm3) and can nevertheless be handled (moved). This was previously not possible with uniaxial methods. The key here lay in the development of materials. Setting the correct particle size distribution was particularly demanding. More than 100 tests with different powder mixtures were necessary to achieve the correct microstructure and balance between grain and pore ratio.

Furthermore, the Zell plant is currently developing a new manufacturing process based on the technology of "porous sintered materials". For competitive reasons, however, we are not yet able to give any details.

Further information on the advantages compared to the current casting solution has been elaborated with many pictures in the presentation.

Component Specification

Density (g/cm3): 4.0
Tensile Strength (MPa): >18
Hardness (HV0.2): 160-240

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