Patent ID: 7803313

Claim:
A method for forming a unitary component from at least first and second powder metallurgy compacts, the method comprising: injection molding a first powder metallurgy compact having a first surface that is formed by a mold; injection molding a second powder metallurgy compact having a second surface that is formed by a mold; fluidizing the first and second surfaces by applying thermal energy to the first and second surfaces; while the first and second surfaces are fluidized, placing the first and second surfaces directly in contact with each other, wherein additional material is not applied to the first or second surfaces prior to placing the first and second surfaces in contact with each other; wherein after the fluidized first and second surfaces are placed in contact with each other, the fluidized first and second surfaces solidify to form a bonded structure; and thermally treating the bonded structure to fuse the first and second compacts into a unitary component.