The following article on high-strength sinter parts appears courtesy of CTI Symposium USA. The 2026 show takes place May 19-20, 2026, in Novi, MI.  Powder metal technology is well known for products used in the automotive industry. With the shift to electric powertrains, key requirements such as component strength had to be adapted. This has been successfully achieved by developing and implementing new innovative processes to withstand the loads required in electric axles. Powder metal parts such as planetary gears or disconnect systems can even combine these properties with a significantly lower product carbon footprint compared to conventional steel. The disconnect system The primary function of an e-axle disconnecting system is to improve the efficiency and performance of battery electric vehicles by automatically decoupling the transmission shaft from the wheels when no power is required from the electric motor. As soon as power is required, the connection is closed again. Various concepts for disconnect units are available on the market, utilizing shifting components such as dog clutches or sliding sleeves to achieve the mechanical disconnecting function.  The key functions of a disconnecting system are: Energy Efficiency: By disconnecting the e-axle when it is not needed (e.g., during highway cruising when only one axle is sufficient), the system reduces power consumption, which in turn can extend the vehicle’s range.

Performance Optimization: It allows the vehicle to perform optimally by engaging or disengaging the e-axle according to driving conditions, ensuring that the required power available when needed. Component Wear Reduction: Disconnecting the e-axle when not in use can reduce wear and tear on the drivetrain components, resulting in longer component life and lower maintenance costs. Driving Dynamics: Improves driving dynamics by providing better traction and stability control. For example, it can disconnect at high speeds to improve fuel efficiency and re-engage at low speeds or off-road conditions to improve traction. Temperature Management: Helps manage the thermal load on the powertrain by disconnecting during periods when high performance is not required, preventing overheating and improving component life. The Powder Metal Process Route – High strength and Energy Efficient The powder metallurgy process is known for its ability to efficiently produce high volume parts with comparatively low energy consumption. The following chart (Fig.2) gives an overview of all possible process steps. Low loaded parts can have a process route that ends directly after sintering, whereas highly loaded parts such as disconnect sleeves require additional operations like sizing or heat treatment.