Novel Powder Metallurgy Compacts with Internal Structures

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A novel manufacturing technology was previously developed, with a utility patent applied for, which is capable of producing a hollow component in only two steps that is completely enclosed in metal. The technology leverages the powder metallurgy press-and-sinter technique to densify metal powder into a solid body completely encapsulating an internal structure. These internal structures most often are composed of a metallic shell containing a paraffin wax core. Firstly, metal powder is pressed ("compacted") around a solid metal shell containing a soft wax-filled core to form a metal compact or part containing an internal structure. Subsequent heating ("sintering") of the compact at particular conditions allows for the paraffin to melt out of the compact, thus producing a hollow metal part.