Powder Metallurgy Review Autumn 2014

VOL. 3 NO. VOL. 2014 AUTUMN/FALL REVIEW

KEYSTONE POWDERED METAL COMPANY HOT ISOSTATIC PRESSING HARDMETAL STANDARDS

Published by Inovar Communications Ltd ipmd.net PowderMetallurgyReview Feb2014.pdf 1 1/14/14 10:02 AM

Publisher & editorial offices Inovar Communications Ltd 2 The Rural Enterprise Centre POWDER Battlefield Enterprise Park Shrewsbury SY1 3FE METALLURGY United Kingdom Editor & Publishing Director REVIEW Paul Whittaker AUTOMOTIVE HEAVY INDUSTRY AEROSPACE Tel: +44 (0)1743 454992 Email: [email protected]

Managing Director Nick Williams Tel: +44 (0)1743 454991 THE FUTURE OF PM SOLUTIONS Email: [email protected] Accuracy of contents A classic comeback story Whilst every effort has been made to ensure the accuracy of the information in In an upbeat presentation at the PM2014 World Congress HAS ARRIVED! this publication, the publisher accepts no responsibility for errors or omissions or in Orlando, Florida, MPIF President Richard Pfingster told for any consequences arising there from. international delegates that the Powder Metallurgy industry’s Inovar Communications Ltd cannot be held recovery since 2010 was “a classic comeback story, in The potential of powder metallurgy responsible for views or claims expressed is only limited by one’s imagination… by contributors or advertisers, which are not which an industry rallies an inner strength rooted in its long necessarily those of the publisher. tradition of entrepreneurial grit.” To that end, from developing new materials Reproduction, storage and usage that lead to property advancements or Single photocopies of articles may be made This sense of optimism, which could be felt in both the PM process e ciency, to working with for personal use in accordance with national PM2014 congress sessions and in the exhibition hall, was copyright laws. Permission of the publisher further lifted by the enthusiasm surrounding the youngest our customers to and payment of fees may be required for all other photocopying. branch of the Powder Metallurgy industry, metal Additive achieve the most cost All rights reserved. Except as outlined above, Manufacturing. The MPIF’s new Additive Manufacturing for e cient solutions no part of this publication may be reproduced, Powder Metallurgy conference (AMPM), which was held in stored in a retrieval system, or transmitted parallel with the World Congress, was a huge success with using PM technology, in any form or by any means, electronic, photocopying or otherwise, without prior the AM sessions filled with delegates keen to learn about the we are committed to permission of the publisher and copyright technology and its opportunities. providing powder owner. metallurgy Submitting news and articles There was also much to celebrate in terms of conventional solutions…serving We welcome contributions from both PM in Orlando, with the annual Design Excellence Awards industry and academia and are always once again demonstrating to the world that PM continues our customers interested to hear about company news, innovative applications for PM, technology to expand the boundaries of what can be achieved with the in every part of developments, research and more. technology (page 85). Keystone Powdered Metal Company’s the world! Please contact Paul Whittaker, Editor Grand Prize winning automotive planetary carrier assembly, Tel: +44 (0)1743 454992 featuring the ground-breaking use of Powder Forged helical And, along the way, Email: [email protected] pinion gears, is a prime example of the PM industry’s be assured we will Subscriptions continuing drive for innovation. In this issue we profile the Powder Metallurgy Review is published on company and report on the development of the award winning continue to invest a quarterly basis. It is available as a free assembly (page 45). in manufacturing electronic publication or as a paid print subscription. The annual subscription charge capacity to support is £85.00 including shipping. Rates in € and Away from conventional PM, we also report on award industry growth globally US$ are available on application. winning Hot Isostatically Pressed parts as announced in the HIP Parts of Excellence competition at the HIP’14 while providing design, Advertising opportunities Contact Jon Craxford, Advertising Director, conference in Stockholm this June (page 55), and in a return process, and material system to discuss how we can help promote your to the important subject of PM standards, we review the education wherever it is needed. products and brand, both online and in print. development and challenges of standards in the hardmetals Tel: +44 (0) 207 1939 749 industry (page 69). Fax: +44 (0) 1743 469 909 Email: [email protected] Paul Whittaker Design and production Editor, Powder Metallurgy Review Inovar Communications Ltd. ENGINEERING THAT MOVES THE WORLD ISSN 2050-9693 (Print edition) ISSN 2050-9707 (Online edition)

Choose the best in sintering

24 45 58 69 87

Critical Process Parameters in MIM Sintering Furnaces in this issue

The accuracy of dimensional tolerances of sintered 45 Keystone Powdered Metal Company: 79 PM2014 World Congress: Global PM MIM parts is limited, especially in the case of larger Pioneering the Powder Forging of industry sustains growth momentum geometries. One reason is green density fluctuations automotive helical pinion gears Powder Metallurgy Review reports on the three introduced during high-pressure injection molding Keystone Powdered Metal Company was awarded presentations in the ‘Global Trends’ plenary leads to inhomogeneous shrinkage behavior at Ipsen’s TITAN DS furnace is a MPIF Grand Prize for its automotive planetary session at the PM2014 World Congress held in elevated sintering temperatures. Another reason is now available in a smaller carrier assembly at the recent PM2014 World Orlando, May 18-22. large temperature gradients in the furnace hot zone size, specially designed for Congress. The assembly utilises Powder Forged cause geometrical distortions, even in part areas with titanium and other high alloy helical pinion gears in what is an industry first. 85 MPIF PM Design Excellence Awards 2014: rather homogenous density distributions. materials. Paul Whittaker, Editor of PM Review, reports on Innovations drive new applications the long history of innovation at Keystone and the The annual Metal Powder Industry Federation’s • High temperature development of its helical pinion gears. By examining different factors for determining (MPIF) Powder Metallurgy Design Excellence unwanted temperature gradients in MIM vacuum capabilities up to 3,000 °F Awards provide a showcase for the PM 55 HIP’14: Highlights from the 11th International furnaces, we are able to evaluate the process (1,640 °C) community, demonstrating the latest design and Conference on Hot Isostatic Pressing parameters and present possible improvements by • All-metal or graphite hot manufacturing developments that enable PM to th utilizing tight control and accurate design of heating zones are available HIP’14, the 11 International Conference on Hot move into new markets. Isostatic Pressing, took place in Stockholm, elements and hot zones, as well as advanced process • 18” x 18” x 24” (457 mm x Sweden, from June 9-13. Dr Stephen Mashl, gas management systems, for commercial use in large 457 mm x 610 mm) work Chairman of the International HIP Committee series production environments. zone (IHC), reports on highlights from the event including winners of the HIP Parts of Excellence Find out about critical process parameters for MIM competition. regular features *Ipsen also offers debinding and sintering heat treatment furnaces, testing results and sintering furnaces in a variety of 5 Industry news more by visiting the link below. larger sizes. 69 PM Standards: Hardmetals for cutting applications, wear parts and structural 88 Advertisers’ index applications 88 Events guide In our second report on PM standards, Dr Bryan Roebuck and Eric Bennett from the UK’s National Visit IpsenUSA.com/Critical-Process-Parameters Physical Laboratory focus on the importance of

to view the full technical presentation. standards in the hardmetals industry.

Metaldyne and Stackpole Sandvik plans joint venture enter into Joint Technical with China’s Zhuzhou Agreement Cemented Carbide Group

Metaldyne, LLC and Stackpole International, Engineered Sweden’s Sandvik AB has announced the signing of a Products Division, have agreed to share technology under letter of intent with Zhuzhou Cemented Carbide Group Co., a technical agreement to allow both companies to expand Ltd, China, to form a joint venture for strategic coopera- Fe their product offerings in line with engine fuel efficiency tion. Under the agreement the two companies intend to trends. Specifically, the combined expertise of both manufacture products at Zhuzhou Group’s existing facili- companies, it is stated, will support their abilities to offer ties in China, with products being sold and marketed in engine balance shaft systems with integrated variable and outside China. displacement oil pumps. The Zhuzhou Group is the largest domestic manufac- “We are pleased to work with Stackpole on providing turer in China of cemented carbide and its compatible technical solutions in balance shaft assemblies for the tools. “The cooperation with Zhuzhou Group strengthens light vehicle engine market,” stated Thomas Amato, our position in one of our largest markets, China. It is also President and CEO, Metaldyne, LLC. “We look forward in line with our current strategy to become a key player in to the partnership and providing added value to our the mid-market segment, which has been growing in size customers,” added Peter Ballantyne, President and CEO, and importance in recent years,” stated Jonas Gustavsson, Stackpole International. President of Sandvik Machining Solutions. Through this technical alliance Metaldyne and Stack- “Expanding beyond the premium segment in the pole will work together to design balance shaft assembly metal-cutting tool industry is an important part of Sand- systems, based on Metaldyne’s balance shaft system vik’s growth ambitions. This preliminary agreement is a technology combined with Stackpole’s variable displace- significant step in that direction,” added Olof Faxander, ment oil pump technology. Sandvik’s President and CEO. www.metaldyne.com www.chinacarbide.com www.stackpole.com www.sandvik.com

CIP-COLD-ISOSTATIC-PRESSES G WET BAG PRESSES G DRY BAG PRESSES LABORATORY PRESSES

since 1917 PISTON EXTRUDER G LOOMIS PRODUCTS Kahlefeld GmbH CONTINUES PISTON EXTRUDER G PISTON EXTRUDER 16 T - 500 T LOOMIS PRODUCTS COMPANY CONSULTATION AND COMPLETE PLANT DESIGN uy the TOOLING b orig inal · buy quality Metal Powders Stockwiesen 3 · 67659 Kaiserslautern/Germany · Tel +49 (0)6301-79999-70 · Fax +49 (0)6301-79999-92 · [email protected] · www.loomis-gmbh.de www.qmp-powders.com 4 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Autumn / Fall 2014 Powder Metallurgy Review 5 Industry News | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email |

with reliable delivery capacity and Miba opens supply. Since 2010 we invested in GTP announces total USD $51 million as a commit- expanded USA ment to the site in McConnelsville partnership with production facility and its well trained employees. Key Umicore criteria such as logistic and energy Miba Sinter USA, LLC, has officially supply as well as collaboration Global Tungsten & Powders Corp. opened new production facilities at its with persons in charge and partici- (GTP), headquartered in Towanda, McConnelsville site in Ohio, USA. The pants are excellent,” stated F. Peter Pennsylvania, USA, has entered into company, a subsidiary of the Austrian Mitterbauer, CEO of Miba Group. a strategic partnership with Umicore Miba Group, produces high precision Miba currently has 600 employees for the tolling of GTP’s cobalt inter- sintered components for the North at five production sites in the USA. mediate to cobalt metal powder. The American automotive industry. The expansion could add a further cobalt intermediate is generated The Miba factory in McConnelsville 100 employees to the McConnels- from GTP’s recycling centre where started production of components ville site. Miba generates 19% of its customers send their secondary raw in 2010 and had a total area of revenues in the NAFTA markets. materials to be converted to tung- 45,951 ft². The extension represents “Our target is to offer solu- sten and tungsten carbide powders, an investment of USD $8 million, with tions for more efficiency, safety and cobalt metal powders, and tantalum the site now covering 88,414 ft². environmental compatibility to our carbide powders. Umicore is a global “The doubling of our production customers. We are looking forward to material technology group headquar- area responds to the highly positive continuing our successful work and tered in Belgium and is the largest development of the US automotive we see new growth opportunities in cobalt metal powder producer in the industry. Our local to local strategy the United States of America,” added hardmetals market. seeks for a maximum benefit for our Mitterbauer. “Teaming with a responsible customers in long term partnerships www.miba.com partner like Umicore ensures GTP’s continued strong commitment to environmental stewardship,” stated Dr Andreas Lackner, GTP’s President supplier of piston rings to PMG and CEO. PMG moves Polmetasa for more than ten years. GTP, a division of the Plansee into piston ring The acquisition is said to follow the Group, has an additional manufac- growth strategy of PMG after recently turing facility located in Bruntal, business acquiring PTFE know-how and piston Czech Republic, and a secondary raw ring technology to further develop its material collection centre in Kolkata, PMG Polmetasa of Mondragon, global shock absorber components India. GTP’s primary emphasis is Spain, a subsidiary of the PMG business unit, and to be able to offer the manufacture of tungsten and Holding GmbH in Unterterschleis- customers complete and ready-to- molybdenum powders with addi- sheim, Germany, has announced install shock absorber pistons. tional emphasis on other specialty the acquisition of Riken Espana SA The former Riken Espana unit will products. GTP is one of the largest bringing in-house the production of operate under the new name of PMG manufacturers of tungsten powders piston rings. Constanti SA. in the world. Riken Espana had been the main www.pmgsinter.com www.globaltungsten.com

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Change at the top Dynamet at Höganäs Technology

Swedish metal powder producer Inc sold to RTI Höganäs AB recently surprised the International Powder Metallurgy industry with the announcement that Alrik Danielson RTI International Metals, Inc. has has resigned as President and CEO Melker Jernberg has been appointed announced the purchase of Dynamet and that the Höganäs Board of Direc- as the new President and CEO Technology, Inc. for a reported tors has appointed Melker Jernberg of Höganäs AB in place of Alrik US$15.5 million. to be his successor. The change will Danielson Dynamet Technology manufac- The flair and flexibility you need take place in the autumn of 2014. tures products from the company’s Danielson stated that Höganäs was manager of the bus division at proprietary titanium alloys, standard is an outstanding company and Scania AB. titanium alloys and metal matrix that together he and the board had “We are very happy to have composites using Dynamet’s achieved a lot, “However, there recruited Melker Jernberg to advanced PM process. Near-net comes a point when it is time to hand Höganäs,” stated Staffan Bohman, shape preforms and products that over to the next person to lead the Chairman of the Board. “Melker has have been successfully produced group into the next exciting phase. I a solid career and brings with him and commercialised by Dynamet truly wish Melker the best of luck. I relevant experience and compe- include various missile parts as well am convinced that Höganäs will be tence. It is a loss that Alrik Danielson as CermeTi Metal Matrix Composite very successful also in the future.” chooses to leave the company, but (MMC) material for medical implant Melker’s current position is as the Board greatly appreciates his products. Senior Vice President and manager of contribution to Höganäs’ positive In 2012, Dynamet Technology the EMEA region at SSAB, an area of development during his period as announced the receipt of qualification responsibility with an annual turnover CEO.” approval from Boeing for the supply of SEK 20 billion. Prior to SSAB he www.hoganas.com of powder metal Ti-6Al-4V alloy products for structural components on commercial aircraft. This was followed by AS9100C certification in Kennametal CEO 2013. In September 2013, Dynamet Technology received the International Carlos Cardoso to Titanium Association’s Titanium retire Applications Development Award. “This acquisition, RTI’s second Kennametal Inc, Latrobe, Penn- new advanced technology investment A Global Supplier Of Non-Ferrous sylvania, USA, has announced that this year, adds innovative titanium Products Include: Carlos Cardoso, the company’s powder research and development, Chairman, President and CEO, as well as a second distinct powder- Metal Powders with a reputation for Cardoso has served as Kennametal • Copper will retire on December 31, 2014. President and CEO since 2006 based manufacturing technology to Kennametal’s board of directors has RTI’s capabilities,” stated Dawne S - Irregular • QUALITY commenced its search for Cardoso’s Director William R Newlin, Chairman Hickton, Vice Chair, President and - Spherical successor, who is expected to be of Newlin Investment LLC. “We CEO of RTI. • FLEXIBILITY - Dendritic announced before the end of the year. appreciate the efforts Carlos has Stanley Abkowitz, Founder of • CUSTOMER SERVICE Cardoso has served as Kennam- made on behalf of the company and Dynamet Technology, stated, “We • Copper Alloys etal President and CEO since January look forward to working together with look forward to becoming part of • NEW PRODUCT 2006, and was elected Chairman him to achieve a smooth transition in the innovative team and culture at • Tin DEVELOPMENT two years later. He joined the leadership.” RTI. Our common view of the vast • Press-ready company in April 2003 as President “I’ve often said to our employees market opportunities and applica- of its Metalworking Solutions and and publicly that seven to ten years is tions for the continued development premix bronzes Makin Metal Powders (UK ) Ltd has achieved its current position Services Group and subsequently was the optimum time period for a Chief and use of Dynamet Technology’s • Infiltrants appointed executive Vice President Executive to manage most effectively. advanced powder metal technology as one of the leading Copper and Copper Alloy powder producers and Chief Operating Officer. With this in mind, I’ve worked regu- make joining with RTI the ideal path • Speciality powders in Europe by supplying the powders that match customer “Carlos Cardoso has served larly with the board on management forward to accelerate progress and technical specifications in the most cost effective manner on a well as a strong leader through an succession,” added Cardoso. market acceptance.” consistent basis, batch after batch. important time in the company’s www.kennametal.com www.dynamettechnology.com history,” stated Kennametal Lead www.rtiintl.com Makin Metal Powders (UK) Ltd

significant energy savings for our SKF to establish customers,” stated Tom Johnstone, Rio Tinto opens $30 million Global SKF President and CEO. “This newest metal powder centre will strengthen our global Technical Centre in network of technical centres that annealing facility United States support each of our key regions. in China The Naperville, Illinois-based R&D SKF, a leading global supplier of centre will complement our existing Rio Tinto has confirmed the opening bearings with its headquarters in technical centre in Plymouth, MI, and of a new metal powder annealing Gothenburg, Sweden, has announced help drive our growth ambitions for facility in Suzhou, China. The US $5 plans to build a new 12,100 m2 facility the US market.” million investment will expand Rio in Chicago, USA. The company plans Over the past five years invest- Tinto’s metal powder capacity by 8,000 to initially invest some $30 million in ments of over $2.5 billion have been tonnes a year. “The opening of this the project and will employ around 80 made by SKF in the United States, plant is an important milestone for Rio engineers within the first four years both by building new facilities and Tinto’s Iron & Titanium business and of operation. Eventually the facility the acquisition of the lubrication a unique opportunity to participate in may house up to 200 employees. company Lincoln Industrial and most a rapidly growing market. Today we The Global Technical Center recently Kaydon Corporation. are seeing growth in demand for our Americas (GTCA) joins two centres “The GTCA will bring world-class powders product by more than 10% a recently opened in China and India, SKF knowledge and experience year in China,” stated Alan Davies, Rio while two new European centres are closer to our customers in order to Tinto Diamonds and Minerals Chief under construction, one in Holland increase the speed of delivering new Executive. and one in Sweden. products and solutions to market,” In addition to the new annealing “One of SKF’s driving forces is stated Poul Jeppesen, President of furnace, Rio Tinto Suzhou consists of to continue to deliver world leading SKF USA Inc. metal powder blending and pack- research and innovation and to www.skf.com aging operations. develop products which deliver www.riotinto.com

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The organic increase in profit was GKN posts strong £9 million, including £5 million of Schunk Group performance restructuring charges reported in 2013, achieves growth partially offset by the £4 million nega- figures for its PM tive impact of currency translation. despite challenging division “We have continued to outper- conditions form our key markets and report GKN plc results for the six months good underlying financial results in Schunk Group, based in Heuchelheim, ended 30 June 2014 showed strong spite of sterling’s strength and some Germany, has announced that it performance figures for the group’s end market weakness. We expect achieved a turnover of close to €940 Powder Metallurgy Division, the these trends to be maintained in the million in 2013, the second-highest world’s largest manufacturer of second half. GKN is continuing to turnover in the history of the company, sintered components. GKN Powder make encouraging progress against despite what are described as difficult Metallurgy comprises GKN Sinter its strategy,” stated Nigel Stein, Chief economic conditions. Metals and Hoeganaes. Executive, GKN plc. The Group stated that although GKN Powder Metallurgy sales GKN Powder Metallurgy continued sales in Western Europe declined for the six month period to 30 June its strong product and operational because of market conditions, these were £471 million. Strong growth development in engines and trans- remain the most important markets was achieved in North America and missions, being awarded more than for Schunk. The highest growth rate China whereas growth in Europe was £75 million of annualised sales in of all regions was achieved in Eastern more in line with vehicle production. new business. It also won a number Europe. Growth in sales was also Sales in South America fell due to of quality awards including Paccar’s achieved in Asia and in the USA. weaker automotive markets. Around “Quality Achievement Award 2013”, “2014 is also proving to be a chal- 80% of GKN Powder Metallurgy Schaeffler’s “Best Technical Coopera- lenging year but Schunk is very well Heat treatment at 1250°C (2282°F) sales are to the automotive market, tion” and Nexteer’s “Perfect Quality positioned in all business areas,” with the balance to other industrial 2013” award. stated Dr Arno Roth, Schunk’s CEO. customers. www.gkn.com www.schunk-group.com We offer the complete material and heating solution

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the largest single investment in Sales volumes continue to grow the 90-year history of the Plansee Carpenter Technology reports at Plansee Group Group,” stated Schwarzkopf. full year results Optical Ensuring secure supplies of raw The Plansee Group, based in Reutte, first time China has become the third materials globally will continue to Carpenter Technology, a leading producer of special alloys, Particle Analyzers Austria, has stated that in the largest country for Plansee Group be a key issue. Molymet is a listed titanium alloys, gas atomised metal powders and high alloy 2013/14 fiscal year ending February sales, behind the USA and Germany. company and the world’s largest steels, reported a fall of 4% in net sales to $1,783 million 28, 2014 it increased its sales In terms of world regions, sales processor of molybdenum ore (excluding surcharges) in the financial year ending June 30, volume by 17% and achieved sales of in Europe remained stable compared concentrates, with a global market 2014, despite a 6% rise in the volume of material shipped. €1.2 billion. The Group made invest- with the previous year at a level of share of more than 35%. Net income was reported as $132 million. ments of €280 million. “Although 48%. While sales in America dropped Plansee’s hardmetals division, William A Wulfsohn, President and CEO, stated that falling raw materials prices meant from 31 to 28%, sales in Asia rose Ceratizit, acquired an 80% share overall company earnings and margins improved sequen- that sales remained at the same level from 21 to 24%. More than half of in the North American tool manu- tially from the third to fourth quarters of fiscal year as last year, we were able to signifi- Group sales were achieved in the facturer Promax Tools LP during 2013/2014, and that the sales backlog in the Specialty cantly increase the volume of sales,” mechanical engineering, automotive this period. The company has a Alloys Operation (SAO) was up 32% year-on-year. SAO sales If you are looking stated Dr Michael Schwarzkopf. and consumer electronics sectors workforce of 70 in Rancho Cordova, of premium alloys and stainless steels for the year were for state-of-the-art The drivers for the upturn in the and it was stated that 30% of sales California. This investment follows $1,345 million (excluding surcharges) whilst sales for the optical particle company’s performance included were achieved with products that are the acquisition of a share in German Performance Engineered Products (PEP) segment were products for the consumer elec- less than five years old. tool manufacturer Günther Wirth $498.6 million ($520.1 million in 2013). analyzers, look tronics sector and tools for the The Plansee Group increased in the previous year. Schwarzkopf The PEP segment includes the Carpenter Powder no further than mechanical engineering and auto- its share in the Chilean company commented, “These M&A activities Products division which contributed $48.6 million to sales RETSCH motive industries. Demand picked Molymet from 14 to 20% last year. underscore Plansee Group’s inten- ($55.9 million in 2013). Carpenter is one of the world’s TECHNOLOGY. up noticeably in the second half of The most recent figures show that tion to take a leading position in the leading metal powder producers using the Micro-MeltTM gas the year, stated the Group. Previous Molymet, which employs 1,535 world market for molybdenum and atomisation process. growth rates of China as a global staff, achieved annual sales of $890 tungsten materials.” Carpenter Technology opened a new facility in Athens, n Particle size and economic powerhouse are lacking, million. “At a total value of €400 www.plansee.com Alabama, USA, in January 2014 for the production of particle shape stated Schwarzkopf; however for the million, the share in Molymet is premium special alloys. ‘’We produced 1000 tons of saleable analysis product in the fourth quarter and are making significant n Size range from progress obtaining internal and customer qualifications. 1 µm to 30 mm These qualifications are critical to enable us to support our n Analysis of growing demand with Athens’ capacity,’’ stated Wulfsohn. powders, granules www.cartech.com and suspensions www.eisenmann.com www.ruhstrat.com PMG Pennsylvania expansion underway The Powder Metal Group (PMG), headquartered in next Fussen, Germany, is expanding its facility in Philipsburg, generation Pennsylvania, USA, due to the company’s growing business high temperature in the region. The $4 million development will see an additional roller furnaces 27,000 ft2 expansion to the company’s current 55,000 ft2 building and allows for additional manufacturing volume and further storage space. Construction for the project – Modular roller hearth sintering furnaces began in May and is expected to be complete by November 2014, according to a report in the Centre Daily Times. – Powder reduction furnaces up to 2600 °C “We’re hopeful to have it done in October for it to be operational in November,” stated Fredi Roos, PMG Pennsylvania – Custom designed MIM furnaces President and CEO. PMG Pennsylvania is focused on the production of – A World wide service and manufacturing network components used in shock absorbers. The company employs about 100 people and is expected to add 15 jobs at the plant in the next two years. www.pmgsinter.com www.retsch-technology.com Visit us at Euro PM 2014 in Salzburg, 21. – 24. September, Stand No. 8

and CEO Carlos Cardoso. “We remain Kennametal pleased with the progress related to Global car markets sees strong sales the integration of our Tungsten Mate- in good shape in The POWDERS that rials Business, which is currently growth in fiscal ahead of schedule. We will continue first half of 2014 to manage our business and control year 2014 The latest figures reveal that most what factors we can.” global automotive markets continued Cemented carbide producer Excluding TMB, Industrial sales make the PRODUCTS to show growth in the first half of Kennametal Inc., headquartered increased 11% in transportation, 2014. North American vehicle produc- From the global leader in P/M and MIM powders in Latrobe, Pennsylvania, USA, has 9% in general engineering, partially tion moved 4.3% ahead year-on-year reported an increase in sales of offset by a 1% decrease in aerospace to 8.795 million units, of which light 10% to $2.837 billion in the fiscal and defence. The transportation vehicle production showed 4% growth year ended June 30, 2014. The sales market benefited from increased to 8.567 million units. In the USA light increase was largely driven by the demand in the light vehicle markets vehicle production increased by 4.4% acquisition of the Tungsten Materials and general engineering increased to 5.8 million units, Mexico increased Take innovation to the next power with AMETEK, the Business (TMB). Operating income due to continued demand from distri- by 7.2% to 1.586 million, but Canada leader in powder metallurgy since 1970. was $263 million ($296 million in bution channels. Sales increased in saw a small fall of 1.9% to 1.18 million 2013). all geographies, up 15% in Asia, 6% units. Light vehicle sales in the USA “During the final June quarter, in the Americas, and 4% in Europe. Whether you’re producing components for automotive, expanded by 4% to 8.1 million units in we saw accelerating growth and For the year ahead Kennametal the first six months of 2014. aerospace, medical, marine or lock hardware applications, ongoing strength in our served expects organic sales growth ranging In Europe (EU28+EFTA), car sales industrial markets; however, certain from 3 to 5% with total sales growth AMETEK Motor Vehicle Series, P/M Stainless, MIM, increased by 6.2% in the first half of sectors are still challenging,” stated between 5 and 7%. the year to 6.852 million units, helped Ultra Stainless and Titanium powders can be custom Kennametal Chairman, President www.kennametal.com by strong sales in the UK (+11%) and formulated to your exact specifications. Spain (+18%) and more moderate increases in France (+3%), Germany Regardless of the volume and properties you require, Arcam reports 21% during the first quarter the majority (+2%) and Italy (+4%). Germany, increase in first went to customers within the ortho- Europe’s largest car producing AMETEK has the ideal solution. Using proprietary paedic implant or the aerospace country, saw production increase by methods for manufacturing superfine metal powders industry, the company stated. 6% to 2.911 million units in the first half 2014 sales and roll-compacted powder, there’s a formulation In June Arcam launched Inconel six months. Swedish Additive Manufacturing 718 as a qualified material for use in Russia continues to experience a that’s right for you. equipment manufacturer Arcam the company’s EBM systems. “With shrinking automotive market with an AB has reported a 21% increase in the introduction of Inconel 718 our 8% decline in sales to 1.229 million Our powder allows you to provide innovative products sales for the first six months of 2014. customers in the aerospace industry units compared with the same period Trailing twelve month sales amounts can now further expand the range last year. Brazil and India also saw that add value to your existing capabilities, help you to 218.3 MSEK and earnings amount of components that they produce in declining sales at 1.584 million develop new markets, and meet your customers’ to 11.7 MSEK. their EBM machines.” units (-7.3%) and 1.290 million units unique needs. In February 2014 the company “In addition to the acquisition (-3.2%) respectively. However, China acquired the powder producer AP&C of AP&C we are in rapid organic reported a rise of 12.1% in passenger from Raymor Industries in Canada. growth. We thus continue to recruit car production to 9.708 million year- AP&C is a leading manufacturer qualified employees in order to on-year and an 11.2% rise in car of high quality metal powder and meet the expectations from our sales to 9.634 million. supplier of titanium powder to Arcam customers. During the period we Japan saw a 9.1% increase in since 2006. “Titanium powder is an have strengthened our service office passenger car production to 4.320 Innovative & Advanced Metallurgical Technology important part of our offering and in China, the support organisation in million driven by a 25.6% surge in with this acquisition we have secured Sweden and the sales organisation. production of mini-cars (under 660cc) P.O. Box 427 • Route 519 access to the best technology for Through the acquisition of AP&C and to 1.012 million in the first half of Eighty Four, PA 15330 USA Tel: +1 724-250-5182 • Fax: +1 724-225-6622 the production of high quality metal through recruitment the number of 2014. Domestic demand for new cars powder for our customers,” stated employees has increased from 55 to in Japan rose by 11% to 2.6 million in Email: [email protected] Arcam. 113 since June 2013. We will main- the first half year. Korea reported a Arcam reported strong demand tain an ambitious recruitment pace in 2.6% rise in automobile production to www.ametekmetals.com from the aerospace industry. Sales order to further develop our tech- 2.243 million units in the six months of the company’s new large system, nology and offering and thus exploit to end June with exports increasing Arcam Q20, have gained momentum the present business situation,” by just 0.4% to 1.596 million due in and resulted in eight system orders. stated Magnus René, CEO Arcam AB. the main to a strong Won and weak Of the 11 systems that were delivered www.arcam.com markets in Eastern Europe.

EOS marks its 25th anniversary with move into new technology and customer centre

Additive Manufacturing (AM) systems supplier EOS has recently moved into a new Technology and Customer Centre in the Krailling Innovation Mile, Munich, Germany. The new EOS Technology and Customer Centre in Dr Hans J Langer, founder and CEO of EOS, stated, Krailling, Germany “This new building represents a further milestone for EOS and is an expression of our company’s growth and specific architectural, spatial and workplace concepts. success story over the last twenty-five years. We operate The architectural concept renders the three key principles in a market that is highly dynamic and which offers a huge of the company’s business strategy – innovation, quality potential. In the past we almost exclusively served the area and sustainability – both visible and tangible. The facility of Rapid Prototyping, whereas now, Additive Manufac- operates on the basis of an integral, sustainable energy turing enables industrial applications in series production. concept.” This new building gives us more space in which to grow, “In line with our corporate objectives, right from the allowing EOS to continually adapt to new market conditions start the emphasis was placed on the building’s functional and customer segments. Moreover, the new customer and ecological efficiency. Both its construction and opera- centre gives us the spatial flexibility we need to allow us to tion were conceived with all due consideration for the jointly develop current and future application solutions in efficient use of resources and energy-efficient building. Additive Manufacturing together with our customers.” In this way, the EOS building concept already complies Christian Kirner, the company’s COO, stated, “With a with the requirements of tomorrow – apt reflection of the floor space of 17,000m², the building is able to accommo- nature of the technology offered by EOS,” added Kirner. PM Reviewdate 08_2014 an additional 175x125_Layout 300 employees, 1 06.08.2014 while its 12:23design Seite follows 1 www.eos.info

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For alloying, a master Höganäs explores alloy with composition lower cost route of 60%Al/40% V and particle size of 6 µm to PM titanium was mixed with the fine

components TiH2 powder to achieve Ti-6Al-4V. Sweden’s Höganäs AB, one of the Because of the fine world’s leading ferrous powder particle size, the powder producers, has been exploring the was treated with a production of titanium powder for polymeric lubricant to press and sinter applications using a improve flow proper- process which, the company states, ties for die compacting. Press and sintered titanium gear wheel. As-sintered could reduce the cost of Powder The die pressed treated (left) and green (right) (Courtesy Höganäs AB) Metallurgy titanium components by powder showed good up to 75% compared with the use of surface quality, green density (87%) sintering because the molar volume

atomised Ti powders. and green strength when warm of TiH2 is larger than that of Ti or Robert Frykholm stated in compacted at 600 MPa. Sintering at Ti-6Al-4V. An example of a titanium

his presentation “Ti Alloys in PM 1300°C in H2 plus vacuum at 1300°C gear wheel in the green and sintered Applications” at the PM2014 World resulted in densities up to 99.5% TD states is shown in the figure. Congress, Orlando, USA, May 19-22, and sufficient chemical purity. Frykholm stated that Höganäs

that Höganäs has been using a pilot In contrast to low levels of dimen- plans to expand the TiH2 powder powder production unit capable of sional change experienced in ferrous facility to around 60 kg/day and to producing 10 kg/day of hydrogen- PM parts, the sintered Ti parts saw carry out further development work ated Ti powder or hydrogenated linear shrinkage of 14% using the on microstructures and mechanical

pre-alloyed powder having particle TiH2 as the base powder. Shrinkage properties. size of 6 to 10 micron. was expected to be substantial during www.hoganas.com

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Ames develops reduces wear and increases bearing Endecotts expands LPW Technology establishes MaterialsScience life. Francesc Cabestany stated in a new Powder presentation that the new bearing its range of sieve new US subsidiary for metal Metallurgy design involves the use of a double shakers AM powders layer sintered porous bearing with bearing design an external copper-base layer Endecotts LPW Technology, a supplier of optimised metal powders for with low friction providing the contact area between Ltd, based in Additive Manufacturing (AM) systems based in Daresbury, Acrawax® C coefficient the axle or shaft and bearing. London, UK, has Cheshire, UK, has formally established a US subsidiary, The developed Cu-base external announced a LPW Technology Inc. Opened in June 2014, the LPW Tech- Lubricant layer is said to facilitate the rapid new addition to nology Inc. office is situated in Pittsburgh, Pennsylvania, and The Powder Metallurgy (PM) formation of a hydrodynamic oil film its range of sieve provides local support and sales to a growing number of industry continues to make during running-in with the resulting shakers, the customers in the US. advances in the performance of one reduction in the coefficient of friction Octagon 200CL. “Our global client base continues to show encouraging of its longest established products, to very low levels (<0.05) in a few The sieve growth and the time feels right for this significant expan- sintered self-lubricating bearings. seconds. Due to these low values of shaker is sion into the US,” stated Phil Carroll, Managing Director of Ames SA, headquartered in Sant friction coefficient, Cabestany said powered by an LPW Technology. “The LPW Technology Inc. office is headed Feliu de Llobregat, Spain, is one that initial power consumption of the electromagnetic by John Hunter, an expert in Additive Manufacturing with of Europe’s leading PM part and system during repeated start-ups drive which has considerable knowledge of powder manufacture.” Working self-lubricating bearing producers, can be significantly reduced. no rotating parts making it main- alongside John Hunter is Donna Williamson, Customer and the company reported at the A further enhancement of the tenance-free and extremely quiet Service Manager, who also has many years of experience PM2014 World Congress, Orlando, performance of the new design of in operation. The vibratory, three- with metal powders. The US team will work closely with USA, May 19-22, that it has devel- sintered bearings has been made by dimensional motion produced by the engineers and researchers at the company’s headquarters oped a new bearing design desig- adding oil wedges to the inner diam- power unit moves the sample over in the UK. ® nated with the trade name LCF eter of the double layer bearing, a the sieve in a unique way resulting in LPW Technology Inc. will develop and provide optimised ® (low friction coefficient). variant that Ames calls LCF-Z . faster, more efficient sieving, while powders specifically for Selective Laser Melting (SLM), It is claimed that the new www.ames.es the rapid vertical movements help to Laser Metal Deposition (LMD) and Electron Beam Melting bearing design not only improves keep the apertures from blinding. (EBM), with standard powders supplied from stock and the friction coefficient but also www.endecotts.com custom development alloys on request. Certified products are available for aerospace applications and in 2014 LPW will add certification for biomedical applications to its existing quality control standards. Duplicating the set-up in the UK, the new office will INSTITUT DR. FOERSTER GMBH & CO. KG ultimately have a well-equipped laboratory with instru- mentation for chemical, physical and bulk powder property testing. This facility will enable the US team to apply a wide Metal Powder Lubricants range of analytical techniques to robustly assess the suit- Setting the Standard for Excellence ability of metal powders for new AM applications, and to ® determine the feasibility of recycling used powders. Acrawax C® Lubricant has been the benchmark for excellence KOERZIMAT HcJ and MS www.lpwtechnology.com in the metal powder industry for over fifty years. This clean- For the determination of burning lubricant generates no metallic or corrosive by- • Coercive field strength HcJ products, which can contribute to environmental emissions and furnace corrosion, and is available in a variety of custom • Saturation magnetization σs Royal Metal Powders to particle sizes. expand production capacity Other features and benefits of Acrawax® C Lubricant include: Royal Metal Powders Inc. has announced that it will increase production capacity for air and water atomised – 100% metal free copper powders, copper alloy powders, and pre-alloyed – Combustible, leaving no residue on sintered parts bronze powders with a 16,000 ft2 expansion of production – Excellent, free-flowing powder mixes equipment, employee service areas and additional ware- – Low die wear and easy part removal from the die housing in Maryville, Tennessee, USA. – Reduced part distortion The expansion should be completed in August 2014 and will include an R&D air atomiser to increase and support new product development. As part of its R&D support, Royal Contact a Lonza representative to learn more: will allow companies to purchase atomising time to develop www.foerstergroup.de E: [email protected] In Laisen 70 · 72766 Reutlingen · Germany · Phone +49 7121 140-312 · Fax +49 7121 140-280 · [email protected] their own products. T: 800 777 1875 www.lonza.com www.royalmetalpowders.com

GKN Sinter Metals celebrates production of one billion seat components with zero defects

GKN Sinter Metals in Bonn, Germany, has supplied seat specialist Keiper with sintered metal components that enable seats to recline since 2000. The parts, referred to as ‘wedges’, reached an impressive milestone recently when the one billionth part was produced, all made with zero The wedges are used in a seat adjustment mechanism defects. In 1998 the first discussions were held with Keiper about replacing traditional metal components in its backrest adjustment system with sintered parts. “We have been producing products from powder metal at this site since 1934 so there was no problem in terms of process. However, Keiper’s high annual demand of 80 million wedges gave us a real headache,” stated Matthias Voss, GKN Sinter Metals Plant Manager. The first volume production order was issued by the OEM in 2000. It comprised 100,000 units per week and manufac- The metal wedges are sintered turing at Bonn started with one press and three employees, states GKN Sinter Metals. Due to the success of the part the “If I had known at that time that my team and I were orders were rapidly increased and the production capacity to produce 320,000 components each day, I would hardly expanded to the current level of seven presses within just have considered it possible. However, we have indepen- one year. dently developed the various processes required and improved them continuously,” stated Blaise Akono, head of the GKN Sinter Metals production cell. By 2001 the Bonn plant had delivered 25 million wedges to Keiper and within four years the deliveries were already at 300 million parts, all with zero defects. On several occasions over the years the customer has honoured the team in Bonn for its high quality standards. Today, the manufacturing cell now operates in three shifts with a total of ten skilled workers. Manufacturing processes include pressing, sintering, hardening, tempering, vibratory finishing, drying and hardness testing, while a complex camera system ensures a 100% quality inspection. A special feature is that the parts are produced in three different dimensions that cannot be visually distinguished. The final step, therefore, involves automatic sorting and packaging of the different variants. “The quality assurance concept has been constantly refined,” added Matthias Voss, Plant Manager. “The hardness is checked by an eddy current system. Subse- quently the parts are fed into the sorting unit in the correct position so that the cameras can check the dimensional accuracy and surface finish of the components. Defective parts are sorted out by the system and Worldwide we have now reached one billion parts with zero defects.” Global manufacturer of nodular and spherical aluminum powders, “Currently we have follow-up projects both in produc- pre-alloyed aluminum powders, and aluminum premixes for PM tion and on the verge of starting volume production, including even some more complex components. There- www.ampal-inc.com www.poudres-hermillon.com fore we are very optimistic about the future, especially as the benefits of powder metal technology increasingly In the Americas come into view of development engineers and production Supplier of carbonyl iron and atomized stainless steel powders for managers,” Voss added. the PM and MIM industries www.gknsintermetals.com United States Metal Powders, Incorporated 408 U.S. Highway 202, Flemington, New Jersey 08822 USA 24 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Tel: +1 (908) 782 5454Autumn Fax: / Fall +1 (908)2014 782 Powder3489 Metallurgy Review 25 email: [email protected]

USM 2013 PM Review and PIMI.indd 2 16/01/2013 10:41:40

The difference with the Selective Plansee develops Laser Melting process is that thin Selective Laser layers of powder are applied on a base plate, one after another. A laser Melting process fuses the powder and builds the new for refractory component one layer at a time. Non melted powder can be re-used for the We are recruiting global agents, metals manufacturing of a new part. “Nearly all geometries are imaginable. The You are welcome to join us Plansee SE, based in Reutte, only input we need is a 3D drawing Austria, has developed a Selective from our customer,” stated Bernhard Laser Melting process for refractory Tabernig who is responsible for the metals and has announced that the development of new materials and first components have already been technologies at Plansee. delivered to its customers. The Addi- Bernhard Tabernig (left) and Peter The new process can be used, for tive Manufacturing process has been Singer take a look at some of the example, in medical technology. “We perfected for the manufacturing of refractory metal components have already constructed compo- tungsten and molybdenum products, produced at Plansee nents for X-ray diagnostics. They allowing the production of new and have a particularly complex grid innovative components that could not The conventional powder metal- structure for absorbing the scattering previously be manufactured. lurgical route at Plansee comprises radiation as efficiently as possible,” The company stated that the pressing metal powder, sintering, stated Peter Singer, who along with development process has been chal- forming and machining the metal Tabernig developed the process at lenging, as there is a great difference component. Work-intensive non- Plansee. “Without the new manu- in the melting point and the machina- cutting and cutting processes give the facturing process we could not hold bility of refractory metals compared semifinished products such as sheets, these products in our hands.” to other materials such as steel. blocks or rods their final shape. www.plansee.com

Our Cobalt Powder Your Best Solution for Cutting Costs and Improving Performance

Email: [email protected] 26 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd NANJING© 2014 Inovar Communications HANRUI Ltd COBALT CO., LTD. Autumn / Fall 2014 PowderVisit us:Metallurgy www.hrcobalt.com Review 27

cial sales having already taken place in North America fibre producing industry, where between Kassel and Hannover, PyroGenesis signs $12.5 and Europe. What is more exciting is the demand we are New generation of temperatures up to 3000°C are just finished and the integration of million contract for plasma currently experiencing for this product line worldwide." sintering furnaces commonplace. It is this capability Ruhstrat in the Eisenmann group The customer is looking to PyroGenesis and its which led to a close co-operation now completed, it has been decided powder production systems plasma-based technology to ensure a strategic and from Ruhstrat and between Eisenmann and Ruhstrat. In that PM activities of both compa- for 3D Printing continuous supply of metal powder feedstock for their own Eisenmann 2011, following a number of years of nies will be joined and centralised internal 3D printing production use. cooperation, Eisenmann AG acquired in Bovenden, in order to exchange PyroGenesis Canada Inc., based in Montreal, Canada, has "This contract highlights the success PyroGenesis is Founded in 1888, Ruhstrat GmbH Ruhstrat. know-how and experience. announced that it has signed a contract with a major inter- having with the focused business development strategy has a long tradition in high tempera- Eisenmann entered the PM The first results of this co-oper- national manufacturer for plasma-based powder produc- implemented last year; the effects of which we are ture furnaces. At the end of the 19th industry at the end of the 1990s, when ation have already been demon- tion systems for 3D printing. The contract is for the supply only now beginning to see," noted Pascali, "and it once century, co-operation with Noble it introduced its first high tempera- strated in the joint development of by PyroGenesis of ten of its unique metal powder produc- again underscores the success PyroGenesis is having prize winner Prof Walter Nernst from ture roller hearth sintering furnace. a second generation roller hearth tion platforms to the customer over an 18 month period for in deploying its core plasma technology to niche, high- the University of Göttingen resulted in The Eisenmann system consists of sintering furnaces. Combining a contract value of $12.5 million. The customer's name is margin applications." the construction of the first resist- individual furnace modules, each with Eisenmann’s extensive know-how being withheld for competitive reasons. According to World 3D Printing (Additive Manu- ance heated high-temperature its own roller drive unit, connected in roller furnaces and Ruhstrat’s With this contract in hand, the company's backlog of facturing), a report issued by the Freedonia Group in furnace suitable for temperatures through double gate door systems. long time experience with protec- signed contracts now exceeds $20 million or the equiva- December 2013, world demand for 3D printers, materials up to 3000°C. Since then, Ruhstrat This allows the user to set a unique tive atmosphere, the next generation lent of approximately 350% of the company's revenues and software will rise 21% yearly to US$ 5 billion in 2017. has focused on customised solu- temperature profile and atmosphere, sintering furnaces has been commis- in its previous fiscal year, all of which is expected to be This report also highlights faster growth projections for tions for advanced heat treatment of adapted to the specific needs of each sioned. These new furnaces feature completed by year end 2015. metals, as well as rapid gains in markets such as aero- powdered materials and graphites. In processing step in the sinter process an efficient delubing system with "One of the limiting factors in the full commercialisa- space. the 1990s specialist MIM equipment (delubing, sintering, hardening, an optional direct gas fired section, tion of 3D printing for metal products is the availability of www.pyrogenesis.com for debinding and high temperature annealing etc). With sintering temper- combined with improved energy effi- high-quality, high-purity metal powder," stated P Peter sintering was introduced, including atures up to 1350°C and atmosphere ciency and lowered gas consumption. Pascali, President and Chief Executive Officer of PyroGen- a continuous sintering furnace oper- separation, both traditional as well as The group has furnace manufac- esis. New compact tube ating at around 1500°C. advanced materials could be produced turing capabilities in Germany, US, "Our patented platform can produce these powders In addition to serving the PM with a very high accuracy. Mexico and China. effortlessly. It is a proven product with completed commer- laboratory furnace range industry, Ruhstrat has been building With the brand new office and www.ruhstrat.com continuous furnaces for the carbon manufacturing facilities in Bovenden, www.eisenmann.com from Carbolite

Carbolite, Hope Valley, UK, has announced a new range of compact split and non-split tube furnaces for laboratory use. The 1200°C E-series tube furnaces are ideal for heating small sample volumes and offer excellent temperature uniformity, states the company. The furnaces are available with heated lengths of 150, 300, 450 and 600 mm and a maximum tube diameter of 60 mm. Available tube materials are metal, ceramic and quartz. Optional tube adapters allow for the use of varying diameters up to the maximum of 60 mm in the same furnace, offering increased flexibility. The EST and EVT split tube furnaces are hinged, allowing them to be opened to reduce the cool-down time. In combination with the fast heat up rates, this results in a high sample throughput. The EHC, EZS, EVC and EVZ three-zone models are all available with heated lengths of 450 and 600 mm. The standard slave-control option ensures a longer uniform zone than can be achieved in a single zone furnace. An easy to use angle adjustment option on the vertical furnaces also allows horizontal and multi-angle configurations. www.carbolite.com

parts made from an advanced aero- Avio produces jet space material titanium aluminide engine titanium (TiAl). The material is 50% lighter than the nickel-based alloys typically turbine blades used for low pressure turbine blades. using high power Blades made from the material can reduce the weight of the Electron Beam entire low pressure turbine by 20%. Melting system “Although the material is expen- Avio has 3D printed titanium turbine sive, the weight savings and the fuel Engineers at the Italian aerospace blades for the LEAP, GEnx, GE90 and consumption savings tied to weight company Avio Aero, part of the GE GE9X jet engines (Courtesy GE) reduction more than pay for it,” Aviation group, have developed a added Varetti. Engineers can also process for Additively Manufac- laser-powered 3D printers. change the shape of the blades and turing light-weight metal blades for As a result, one machine can print different blades on the same jet engine turbines from titanium produce eight stage seven blades for machine in a quick succession, which powder. The method builds the the low pressure turbine that goes would be laborious and expensive blades from a titanium powder fused inside the GEnx jet engine in just 72 with casting processes. with a beam of electrons accelerated hours.“This is very competitive with GE will begin testing blades by a 3-kilowatt electron gun. casting, which is how we used to printed for the GEnx engine at its test Buying and selling The gun is reported to be ten make them,” stated Mauro Varetti, facility in Peebles, Ohio, later this times more powerful than the laser Advanced Manufacturing Engineer year. The parts will also go inside the beams currently used for printing at Avio. GE9X, a new jet engine GE is devel- metal parts. This boost in power Avio developed the electron beam oping for Boeing’s next-generation powder metal allows Avio to build blades from melting (EBM) technology together long-haul plane, the 777X. layers of powder that are more than with Sweden’s Arcam. The idea was www.ge.com four times thicker than those used by to improve the manufacturing of and furnace scrap worldwide, since 1946. From aluminum to zirconium and everything in between. Your Vacuum Sintering Solution Precise ◊ reliable ◊ efficient

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Characterisation of AM focus for new New applications for Kanthal fine particles with UK aerospace APMT™ alloy promise Dynamic Image consortium more cost effective high Analysis from temperature sintering A new consortium of UK compa- Retsch Technology nies is being led by GKN Aero- Sandvik Heating Technology, based in Hallstahammar, space in a three and a half year Sweden, states that it is now marketing a unique alloy for Retsch Technology GmbH, Haan, year £13.4 million research and furnace applications that promises superior oxidation and Germany, has introduced its new development programme called corrosion resistance. Camsizer XT system for the quality Horizon (AM). The programme Kanthal APMT is an alumina forming FeCrAlMo control of fine powders. The system includes Renishaw, Delcam, and alloy with mechanical properties suitable for structural offers precise and faster analysis the Universities of Sheffield and applications such as retorts and muffles. As such, it is of particle size and particle shape, Warwick and is backed by the UK’s suited to high temperature Powder Metallurgy sintering at helping to improve the product agglomerates without destroying the Aerospace Technology Institute temperatures of up to 1250°C (2282°F) and above, with air quality, reduce rejects and save individual particle. (ATI). or combustion atmosphere on one side. Kanthal APMT is an alumina forming FeCrAlMo costs, states Retsch. The Camsizer XT offers three The programme will focus The development of this dispersion strength- alloy with mechanical properties suitable for The design of the Camsizer XT is alternative dispersion methods: 1) initially on using AM techniques to ened Powder Metallurgical superalloy started when structural applications such as retorts and muffles optimised for fine samples in a size Dispersion by gravity of pourable, not create near net shape parts which researchers at Sandvik Materials Technology realised that range from 1 µm to 3 mm. Retsch agglomerated particles; 2) Disper- require very little machining. This the unique high temperature capability of the Kanthal® required for heat treatment of, for example, special stain- states that fine particles tend to sion of agglomerated particles by air will dramatically improve the ‘buy FeCrAl-based heating elements could be combined with less steels. agglomerate which makes it difficult pressure, accelerating and dispersing to fly’ ratio of the part by reducing the high temperature creep resistance of Ni-based alloys The product program has now been expanded into a to record the properties of a single the particles through a nozzle with the considerable cost in time and by using a special PM technology and micro alloying. wider range of wide hot rolled plate, bar, rod and forg- particle. Therefore, it is important adjustable overpressure; 3) Disper- material wastage associated with The Kanthal APMT product has until now been limited ings that opens up the possibilities of using the material to have different ways of feeding the sion in liquids with the option of ultra the conventional machining of half page RMPto seamless ad_Layout extruded 1 1/21/2013 tubes 8:34 for componentsAM Page 1 such as in applications such as hot wall sintering retorts, muffles sample to the analysis area in order sound. metal forgings. tube-based Kanthal heating systems and for furnace and transport systems. to get the desired dispersion of the www.retsch.com www.ati.org.uk rollers capable of handling the extreme temperatures www.kanthal.com/construction-materials

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Metal-AM website launched Potential for metal Additive

To serve the growing demand Manufacturing in construction for news and information steelwork industry on metal Additive Manufac- turing, Inovar Communica- highlighted by Arup tions Ltd launched its Metal Additive Manufacturing Structural engineers at global design and engineering website and monthly e-news- consultancy Arup are looking at Additive Manufacturing Sunrock Ceramics specializes in high letter service in May 2014. (AM) to optimise construction steelwork applications in a alumina industrial ceramics for the The Metal-AM website variety of complex building projects. The team at Arup are most severe sintering applications combines news on the latest using the design freedom that AM offers to optimise mate- industry developments with rial usage, reducing costs and cut waste. of the powder metallurgy and The work at Arup highlights the opportunities for the technical ceramics markets. technical articles, conference reports and market information. The e-newsletter use of Additive Manufacturing in the field of construction By using Additive Manufacturing complex individually is a free news service sent monthly to over 8500 industry and engineering. The research also shows that AM has the designed pieces can be created far more efficiently. The professionals worldwide. potential to cut the carbon footprint of the construction traditionally produced steel node is shown on the right www.metal-am.com sector. “We created a redesign of a steel node for a light weight This has tremendous implications for reducing costs and structure using Additive Manufacturing. Arup has a lot of cutting waste. However, most importantly this approach experience with these kinds of structures, for example potentially enables a very sophisticated design, without AIMS develops Powder the tensegrity structure of the Kurilpa Bridge in Australia. the need to simplify the design in a later stage to lower Metallurgy stator for oil & The complex geometry of these kind of nodes are an costs,” added Galjaard. ideal showcase of the possibilities of this new technique,” Arup funded the development work and collaborated gas industries stated Salomé Galjaard, Team Leader, Arup. with a number of partners to realise the designs, including “By using Additive Manufacturing we can create lots of WithinLab, CRDM/3D Systems and EOS. Advanced Interac- complex individually designed pieces far more efficiently. www.arup.com tive Materials Science Limited (AIMS), Peter- borough, UK, is targeting the oil and gas indus- Is your idea going to grow? tries with the development of a new EU-patented technique to Nurture your seed of an idea with produce helicoidal The helicoidal motor stator Harper as your scale-up partner. motor stators. The company has designed a unique near-net-shaped helicoidal motor stator featuring a telemetry hole using Harper helps companies custom engineer Powder Metallurgy. Previously it has not been possible to high temperature thermal systems for incorporate a hole through a metal stator that can resist the abrasive, corrosive and erosive conditions of modern advanced powder processing. day drilling techniques. AIMS Managing Director Mark Hodgkins stated, “This Let us help take your seed of an idea from the lab to full commercialization. is an interesting development for the oil and gas industries as it will give another option on the quest to understand the conditions at the drill head. We have made a significant investment in research and development, which we continue to do, and this patent, we believe, is a major achievement.” With a sharp increase in directional drilling, the price of pulling drills out of the ground costs many millions of dollars every year. This new innovation will give opportunities to dramatically cut these costs, increasing life- cycle and operating efficiencies, stated AIMS. www.aimsltd.com harperintl.com

EOS launches EOS M 290 metal system Optimised metal powders key to to succeed popular EOSINT M 280 success of precision additively manufactured components EOS has recently introduced its new serial production customers. At the EOS M 290 system for the Additive same time, we have also created new MBFZ Toolcraft GmbH, based in The company recently reported Manufacturing of metal compo- optimisation potential in terms of Georgensgmund, Germany, is a that it has been using LPW Tech- nents. The new system, which will build quality for customers from the specialist manufacturer of high-end nology, Daresbury, UK, to provide replace the established EOSINT prototyping space,” added Keppler. precision metal parts and compo- powders for these exacting AM M 280 machine, offers tool-free Despite all the innovations that nents. The company offers a compre- applications. “LPW are ahead of manufacturing of high-quality metal have been incorporated in the EOS M hensive manufacturing service, which other suppliers in terms of the way serial components, spare parts and 290, its central processing elements includes Additive Manufacturing in which they analyse powders under (Metal Laser Melting), to produce the conditions needed to provide Powder analysis at LPW Technology functional prototypes. have been retained: process EOS M 290 Metal Additive Manufac- micro-components of the highest relevant data for AM. They also “EOS has incorporated proven chamber, gas stream, process turing system is equipped with a 400 dimensional accuracy to meet the understand how to use these data to ensure powders are of the highest elements from the M 280 system parameters, etc. This ensures Watt laser generation in the new EOS M 290, constant process behaviour and in demands of a wide range of indus- help us identify an optimised powder quality LPW has developed the but at the same time, the EOS M 290 turn consistent component quality space industry as well for medical tries including biomedical, defence for a specific AM application. LPW capability to characterise powders also allows us to set new standards beyond the EOSINT M 280 and EOS applications. and motor sport. not only provide the powders best fully. Powders are therefore opti- in Additive Manufacturing while M 290. The system is equipped with a Many of Toolcraft’s customers suited to our needs, but also ensure a mised for Additive Manufacturing. expanding our product portfolio for The new EOS M 290 offers exten- 400 Watt laser and can be operated are in the medical technology and secure supply, at an affordable price,” This ability can enhance consist- metal applications and extending sive monitoring functions both for the under an inert (nitrogen) atmos- aerospace sectors, which require the stated Christoph Hauck, Managing ency, quality and significantly reduce our innovation leadership in terms system itself and for monitoring the phere or under argon, permitting use of certified materials. For appli- Director of Toolcraft. costs by managing the degradation of quality management and moni- build process, states EOS. This adds the processing of a wide range of cations in these industries, a secure The properties of the metal of the powders during use in Additive toring,” stated Dr Adrian Keppler, even more extensive quality assur- materials. These include light alloys, supply of certified powders and the powders used directly impact the Manufacturing machines. CMO at EOS. ance to the field of AM. In particular, stainless and tool-grade steels and ability to produce components to efficiency of AM processes and, www.lpwtechnology.com “This new system is designed it makes the system attractive for superalloys. extremely precise specifications are crucially, the mechanical proper- www.toolcraft.de to serve the requirements of our industrial applications in the aero- www.eos.info essential. ties of the finished component. To

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Cremer_1213_Anzeige_210x148_Gelb_V2 Mittwoch, 22. Januar 2014 14:32:56 36 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Autumn / Fall 2014 Powder Metallurgy Review 37 Industry News | contents page | news | events | advertisers’ index | email | | contents pagePM | news | events | advertisers’ CHINA index | email | 2015 International Hoeganaes HIP Committee Corporation holds April 27-29 2015 presents lifetime its fourth Powder Shanghai Everbright Convention & Exhibition Centre achievement Metallurgy awards Seminar in China John C Hebeisen (left) and Dr Gérard The International HIP Committee Hoeganaes Corporation held its Raison (right) both received the IHC China’s largest PM & MIM exhibition (IHC) presented two lifetime achieve- fourth Powder Metallurgy China Lifetime Achievement Award ment awards at the HIP’14 Confer- Seminar in Nanjing City, Jiangsu ence in Stockholm, Sweden, June Since 2002, the IHC has recog- Province, during May. The tech- 9-13, 2014. nised those individuals who have nical seminar, organised by the The first of the prestigious awards made exceptional contributions to Hoeganaes Powder Metallurgy (PM) was presented to John C Hebeisen, the Global HIP Community. Previous School, was designed to introduce retired President of Bodycote HIP NA. recipients include Chuck Boyer the latest technical developments Dr Gérard Raison, a globally recog- (2002), Prof Mitsue Koizumi (2005), Dr and promote the knowledge of the nised technical expert on HIP, retired William Eisen (2008) and Prof Genrikh PM industry. It has been running from Aubert et Duval, was also Garibov (2011). successfully in North America and presented with the award. www.hotisostaticpressing.net Europe for over ten years. The Chinese seminar was launched in 2011 in order to better serve the Chinese market. Proposed ASTM standard for metal Attendees included representatives from automotive OEMs and parts powder bed fusion quality suppliers, as well as other manufacturers of PM products. A proposed new ASTM standard, powder bed fusion are, how to deter- Chaired by Oliver He, Hoeganaes WK46188, Practice for Metal Powder mine the upper and lower limits of China Sales Manager and Tony Bed Fusion to Meet Rigid Quality the process and ensure all compo- Su, Hoeganaes Senior Technical Requirements, describes the opera- nents are exactly the same.” Engineer, the event attracted over 35 tion and production control of powder The proposed standard’s require- customer representatives from more bed fusion machines and processes ments will be applicable for produc- than 21 companies. to meet rigid quality standards. tion components and mechanical test “The seminar is designed to According to Shane Collins, ASTM specimens using powder bed fusion improve our customer under- member and Director, Program with both laser and electron beams. standing of our products and Management at Incodema3D LLC, “Even though the advantages of technology. Attendees enhance their ASTM WK46188 will enhance the powder bed fusion are enormous, knowledge of Materials and PM safety of additively manufactured the process depends on expen- part design. The program improves parts across a variety of industries. sive machines and, therefore, the customer relationships and helps The proposed new standard has been components produced are high value us to understand our customer accepted as a Joint Group project per at a high price,” added Collins. “The challenges in the marketplace. The the Partner Standards Development typical applications are for patient- seminar’s reputation has gained Organization cooperation agree- specific implants and relatively low great popularity in the China Powder ment between ASTM International volume aerospace and defense Metallurgy industry, as demand for Committee F42 on Additive Manufac- related components.” the program continues to grow,” turing Technologies and ISO TC261 on Once approved, primary users stated Jim Shaul, Hoeganaes Vice Additive Manufacturing. of ASTM WK46188 will be tier 1 President Sales and Marketing. “Additive Manufacturing is based and tier 2 suppliers that are setting www.hoeganaes.com on the capabilities of the machines up a powder bed fusion facility or used in the process,” stated Collins. engineers of original equipment “The machines have been historically manufacturers that will use ASTM PM CHINA 2015 Organizing Committee designed for the rapid prototyping WK46188 as a guide for writing POWDER industry, and we are taking those internal standards. METALLURGY Tel: +86-400 077 8909 same machines and now asking them ASTM WK46188 is being developed REVIEW Fax: +86-21-23025505 owder etallurgy to make safety critical components. by Subcommittee F42.05 on Materials Sign up for our free e-newsletter Contact: Maggie Song ASTM WK46188 will illustrate what and Processes, part of F42. www.ipmd.net/enews the critical parameters for successful www.astm.org Email: [email protected] www.cn-pmexpo.com

GKN Powder Metallurgy and McPhy PIM International EPMA takes its New book to boost deployment of solid state now available 2014 PM Summer charts history of hydrogen storage as a free digital School to Poland sintering

GKN Powder Metallurgy and McPhy the storage capacity and charge/ download The European Powder Metallurgy A new book written by Professor

Energy SA have announced a tech- discharge rates needed to help make Association’s Powder Metallurgy Randal German has recently been Powder Injection Moulding Inter- nology partnership agreement to this technology economic,” stated Summer School took place at the published charting the history of the national, the magazine for the accelerate the deployment of cost Peter Oberparleiter, Chief Execu- University of Cracow, Poland, June sintering process. ‘Sintering: From Metal Injection Moulding (MIM) and competitive solid state hydrogen tive GKN Powder Metallurgy. “With I6 – 20, 2014. The popular event Empirical Observations to Scientific Ceramic Injection Moulding (CIM) storage. McPhy, we have found the right welcomed some 52 students from Principles’ describes how the theo- industries, is now available for the Industrial markets already partner to make this technology throughout Europe to the five day ries and understanding of sintering first time as a free digital download. consume large volumes of hydrogen commercially accessible to the course coordinated by Professor José were developed and improved Launched in 2007, the quarterly and in future the gas will play an industrial, fuel cell and future energy Torralba, Universidad Carlos Ill de over time. It looks at how different PIM International magazine quickly important role in storing renew- markets. Through this development Madrid, Spain, in conjunction with products were developed, ultimately able energy as well as in CO free commitment from GKN we believe established itself as the essential 2 Professor Jan Kazior and his team leading to important knowledge and publication for those involved in MIM Lectures included practical hydrogen fuel cell vehicle develop- we can help deliver this important from the University of Cracow. lessons for solving real sintering and CIM worldwide thanks to high demonstrations ment. Solid state storage is stated technology in the medium-term.” Participants had the opportunity to problems. quality editorial content that ranges as being a safe way to store large “At McPhy, we have demonstrated listen to, discuss and solve problems hardness testing. A site visit to the Written by the most cited author in from technology developments and quantities of gas with high density at that solid state hydrogen tech- with PM experts drawn from both Sandvik Polska factory in Katowice his field, this fascinating book laced application reviews to company low pressure. nology is technically and economi- industry and academia. was also organised for students. with people, organisations, critical profiles, industry news and technical McPhy Energy, headquartered in cally efficient. Being a specialist Lectures were complemented by Dates have not yet been finalised steps and important formulations in papers. La Motte Fanjas, France, is a leading in highly automated production the University of Cracow’s labora- for the 2015 PM Summer School a mixture of history, personalities, Nick Williams, Managing Director provider of large scale solid state of complex geometries based on tory facilities where students gained which will take place in Sheffield, applications and insights is essential of Inovar Communications Ltd hydrogen storage. With installations powder products, GKN is a perfect hands on experience looking at the United Kingdom. reading for anyone involved in the and Editor of PIM International, in five countries, most recently at the match for McPhy Energy to accel- technological properties of powders, www.epma.com world of sintering. stated, “The decision to make Berlin Multi-Energy Fuelling station erate the commercial deployment of compaction of powders and micro- www.textbooks.elsevier.com at Schönefeld Airport, McPhy Energy our disruptive and secure hydrogen PIM International available as a has demonstrated the capability and storage technology at a cost that is free digital publication will further power of solid state storage. competitive with traditional hydrogen broaden our readership within the “Clearly hydrogen will be an storage,” stated Pascal Mauberger, PIM industry, and serve to promote important fuel of the future and CEO and President of McPhy Energy. MIM and CIM technology to the its safe storage will be key to its www.gkn.com end-user communities worldwide.” SWASTIK success. Powder metals offer www.mcphy.com “Since our launch in 2007 our subscription base has grown every year and we will continue to serve TUNGSTEN PRIVATE LIMITED subscribers with a high quality print edition of our magazine.” India’s PM15 The PIM International Magazine YOUR PARTNER IN THE HARDMETAL conference Archive It has also been announced & DIAMOND TOOL INDUSTRIES organisers that digital back issues of PIM announce dates International magazine are now MANUFACTURERS AND EXPORTERS OF: being made available as free PDF and issue Call for Swastik Tungsten Private Ltd. The annual PMAI conference regularly downloads, creating a new free-to- • Yellow tungsten oxide Papers access resource for end-users and C -401 Delta Building attracts a large international audience • Tungsten powder Technology Street the PIM community. • Tungsten carbide and cobalt powder Behind Olympia or Bayer Bldg. The Powder Metallurgy Association A comprehensive technical “Over the coming months we Hiranandani Garden, Powai of India (PMAI) has announced dates programme will include a special will be adding to the archive and it TRADERS OF: Mumbai 400076 and issued a Call for Papers for its session focussing on developments in is our hope that this resource will INDIA PM15 International Conference on engineering ceramics. serve to increase awareness of MIM • Nickel powders Tel: +91 22 3378 4343 Powder Metallurgy and Particulate Organisers of the event have technology and allow end-users • Copper powders Fax: +91 22 2570 0458 Materials & Exhibition. The event requested that abstracts of papers access to information on the Cell: +91 98 2232 4433 • Prealloyed powders for diamond tools Email: [email protected] will take place in the Victor Menezes for oral presentation as well as latest commercial and technical Convention Centre at the Indian Insti- posters should be submitted no later developments,” stated Williams. tute of Technology campus, Mumbai, than October 30, 2014. www.pim-international.com India from January 19-22, 2015. www.pmai.in/pm15 www.swastiktungsten.com

“With the introduction of the Arcam launches Inconel 718 our customers in the GE announces Now available a nickel base aerospace industry can now further location of high expand the range of components superalloy process that they produce in their EBM volume Additive as a FREE download for Additive machines”, stated Magnus René, Manufacturing CEO of Arcam. Manufacturing The material properties comply facility

with chemical requirements of UNS with EBM systems GE Aviation N07718 and properties of ASTM has announced Additive Manufacturing equipment F3055-14 specification. plans to bring manufacturer Arcam AB, Sweden, The Inconel process is initially high volume has announced that Inconel 718® available for the Arcam A2X Additive Manu- is now a qualified material for use platform. The machine material facturing (AM) in the company’s Electron Beam parameters and mechanical testing to its facility Melting (EBM) systems. Inconel was done in collaboration with the in Auburn, 718 is a high-strength, corrosion US Department of Energy’s Manu- Alabama, USA. resistant, nickel-chromium based facturing Demonstration Facility at The company superalloy suitable for a range of Oak Ridge National Laboratory. has stated it demanding applications. www.arcam.com will manu- The LEAP engine facture its jet will use 19 AM fuel engine fuel nozzles nozzle at the EFESTO and RPM site, becoming Innovations the first company to mass produce additive components for the jet announce strategic propulsion industry. metal Additive GE will invest $50M in the existing 300,000 ft² facility to prepare for the Manufacturing additional work. Equipment instal- partnership lation will begin in late 2014 and production of AM components will EFESTO, Superior Township, begin in 2015. By the end of 2015, the Michigan, USA, and RPM Innova- plant could have as many as ten AM tions Inc, Rapid City, South Dakota, machines with the potential to grow USA, have announced a long term to more than 50 machines and occupy global strategic partnership to offer a a third of the facility at full capacity. comprehensive range of Laser Metal Freeform part being built by laser The AM fuel nozzle will be used in Deposition (LMD) equipment and (image RPM Innovations Inc) GE’s LEAP engine with every engine services for metal Additive Manufac- requiring 19 fuel nozzles. Once turing (AM). oil and gas, power, mining and manufacturing begins GE will ramp Now available as a FREE PDF download Both companies specialise in heavy industries. The company has up production quickly, starting with metal Additive Manufacturing/3D successfully manufactured some 1,000 fuel nozzles produced annually Printing technology and applications. of the industry’s largest metal 3D to more than 40,000 by 2020. PIM International is the only publication • Available as a FREE PDF download from The partnership will bring immediate Printed components using titanium GE also reported that it is devel- dedicated to serving the global PIM industry, www.pim-international.com/magazine benefit to potential and existing users and nickel superalloys in their own oping 3D-printed parts for the GE9X of metal AM by making available a RPMI 557 laser systems. engine, the world’s largest jet engine comprising the metal (MIM), ceramic (CIM) • Exclusive industry news comprehensive line of LMD machines EFESTO and RPMI have partnered which will be installed on the next- and carbide injection moulding sectors. Don’t • Specially commissioned features and contract services, supported by to commercialise RPMI’s 557 system generation Boeing 777X long-haul miss the latest commercial and technological • Company visits more than 50,000 hours of expertise for third party use, as well as a full passenger jet. in advanced LMD applications. range of smaller systems to address All development of AM compo- developments from this dynamic high-growth • plus conference reports, patents and much more RPM Innovations, Inc. is a leading less demanding requirements. All nents will remain in GE Aviation’s industry..... Laser Metal Deposition services systems retain the core design prin- Additive Technology Center (ATC) provider in North America, special- ciples of the industrially hardened in Cincinnati, Ohio, which is also Print subscriptions are £135 for four issues. For more ising in freeform fabrication, hybrid 557 platform. expected to grow over 300% in size in information visit www.pim-international.com/subscribe manufacturing and repair applica- www.efesto.us the coming year. tions for the aerospace, defence, www.rpm-innovations.com www.geaviation.com Inovar Communications Ltd Tel: +44 (0)1743 454990 2 The Rural Enterprise Centre, Battlefield Enterprise Park Fax: +44 (0)1743 469909 Shrewsbury42 SY1 3FE,Powder United Metallurgy Kingdom Review [email protected] / Fall 2014 www.pim-international.com© 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Autumn / Fall 2014 Powder Metallurgy Review 43

Keystone Powdered Metal Company: Pioneering the Powder Forging of automotive helical pinion gears

At the PM2014 World Congress in Orlando, Florida, Keystone Powdered Metal Company was awarded a Metal Powder Industry Federation (MPIF) Grand Prize for its automotive planetary carrier assembly which, for the first time, utilises Powder Forged helical pinion gears. Paul Whittaker, Editor of Powder Metallurgy Review, reports on the long history of PM innovation at Keystone and the development of its ground-breaking 2014 award winning assembly.

On May 20th this year Keystone History of Keystone Pennsylvania, where it still has its Powdered Metal Company won headquarters and is home to the the Grand Prize in the Automotive Keystone was established in 1927 largest of its production facilities. Transmission category of the Metal when founder B R Reuscher began The company was originally called Powder Industries Federation’s 2014 producing carbon-graphite brushes Keystone Carbon, reflecting the main Design Excellence Awards. This in the town of Emporium, Pennsyl- business of carbon-graphite brush prestigious award, presented at the vania. Shortly after starting the busi- manufacture. It was the mid-1930s PM2014 World Congress, was for a ness the company moved to St Marys, when the production of PM self- 32 part planetary carrier assembly made for the Ford Motor Company that included the pioneering use PROOF of Powder Forging to manufacture the helical pinion gears (Fig. 1). Full density Powder Forged helical gear manufacture is considered by many as a major new milestone for the Powder Metallurgy (PM) industry. Based in St Marys, Pennsylvania, USA, Keystone is the first company to master Powder Forging for this component and the success of this part opens the door for many similar applications, offering the potential to further expand PM’s reach into the Fig. 1 The Powder Forged helical pinion gear is part of a planetary assembly automotive market. containing seven PM components

presses (12–200 ton) and is specifically aligned to serve the needs of the company’s customers who require small structural components.

In-house powder blending At Keystone metal powders are blended in-house, a practice that differs from the majority of the PM industry that buys pre-blended powder materials. The blending process uses certified elemental metal powders, prealloyed powders and diffusion alloyed based powders. To maintain uniformity the company prepares all its material blends in its St. Marys and Cherryville facilities. Fig. 2 From left: Shiz Kassam, Sameer Gudal, Gary Anderson, and CJ Kogovsek Keystone states that the main advan- Fig. 4 Heat treatment is undertaken in-house at Keystone Fig. 5 Keystone was the first PM company to accept award from Richard Pfingstler, president of the MPIF(Courtesy MPIF) tages of in-house powder blending supply a finished machined carrier to its customer are improved size control, less varia- lubricating bronze bearings began One of North America’s tion and fewer, smaller inclusions. the first company to steam treat a As well as the development of Keystone’s Ultra-High Density PM at the St Marys site, leading the way largest PM companies sintered PM part. In the mid-1960s the industry first Powder Forged processes into PM structural parts production Presses, furnaces and tooling the company added induction heat helical pinion gear, Keystone is As well as conventional Powder 2 in the 1950s. The company changed With over 58,000 m of manufacturing Keystone has around 94 compaction treating for gears. A full spectrum credited with the first ultra-high Metallurgy processing and Powder its name to Keystone Powdered floor space across three production presses across its three production of heat treating services is available density and high fatigue alloy Forging, Keystone offers customers Metal Company in 1995, and today sites, Keystone is one of North sites varying in size from 8-1650 tons, today including neutral hardening, engine timing sprocket, the first an Ultra-High Density (UHD) process operates production facilities in America’s largest PM companies. including many multi platen CNC carburising, carbonitriding, induction PM parking gear, the first PM resulting in a claimed higher impact St Marys, Lewis Run, Pennsylvania Keystone offers the full spectrum of presses. There are approximately heat treating, Keyonyx (Keystone’s transmission sprocket and the resistance and better performance and Cherryville, North Carolina. ferrous PM materials and processes, 54 sintering furnaces including proprietary steam treating process) first Powder Forged cam lobes for under load than conventional PM. Keystone’s President and CEO ranging from conventional material belt sintering, induction HT, high and tempering. assembled camshafts, to name Keystone’s UHD process is a double- C J Kogovsek is supported by an systems at 6.4 g/cm3 through to full temperature pusher sintering, experienced management team density Powder Forged materials at integral quench heat treat and Engineering support 3 that includes, among others, Gary 7.84 g/cm . vacuum furnaces. In the early years Engineering support available at “Keystone claims to be the leading edge Anderson, Vice President, Engi- Keystone’s facility in St Marys is the company designed and built its Keystone includes modelling, proto- neering and Shiz Kassam, Director, focused on automotive supply. The own presses and furnaces in-house, typing, testing and failure analysis of PM technology, a bold statement, but Advanced Product Engineering site in Lewis Run was opened in 1997 however as commercial alternatives to determine any design or process one that certainly can be backed by a (Fig. 2). The privately owned company and is also predominantly focused became available it evolved away improvements. Equipment ranging has an annual turnover in excess of on serving the automotive industry. from this practice. from a Scanning Electron Micro- number of industry firsts” $100,000,000 and employs almost The site in Cherryville is equipped When the company began making scope (SEM) to Coordinate Measuring 600 people. with smaller capacity powder metal PM parts the ability to outsource Machines (CMM’s), gear checking tooling to local tool shops was not equipment, fatigue test equipment, just a few. Keystone was also the press/double-sinter operation that an option, so it established its own wear test equipment, impact test first PM company in the industry to offers density ranges up to around in-house tool building capability. stands, four squared test stands, and supply in-house finished machined 7.4 g/cm3, compared to conventional Today, although a significant portion of an engine dynamometer are all open carriers to its customer (Fig. 5). PM process of 7.0g/cm3. Bevel tooling is outsourced, it continues to for use at the company. The company holds a number gears, parking gears, spur gears, maintain a sizable, modern tool shop of patents relating to powder and transmission sprockets are all with full tool room capability including Keystone at the leading blending, powder forming given as excellent UHD candidates. wire EDM, ram EDM, CNC milling, edge of PM processes and operations affecting The main difference between CNC turning and CNC grinding. properties such as strength, hard- UHD and the conventional PM route Keystone claims to be the leading edge ness, density, and wear resist- is that once pressed, sintering Secondary operations in-house of PM technology, a bold statement, ance. Over the years Keystone has occurs at lower temperatures to The company performs all secondary but one that certainly can be backed received numerous awards for avoid a full metallurgical bond. A operations in-house including green by a number of industry firsts. The innovation in process and compo- sizing operation further compresses machining, turning, drilling, grinding, company’s commitment to research nent development. All three of the the pre-sintered part and then a milling, burr removal and heat treat- and development ensures that it is manufacturing facilities are certi- final sintering operation at full ment (Figs. 3 & 4). continually striving to expand the fied for ISO 9001, ISO 14001, and temperature completes the bond. Keystone began heat treating PM penetration of PM into ever more tech- ISO/TS 16949. Secondary operations are also Fig. 3 A bank of tumblers primarily used to tumble rocker clutch components parts in the 1940s and in 1949 it was nological and challenging applications. possible for UHD parts.

Organic growth and depth new opportunities and challenges.” substantial repurposing of existing engine timing sprockets (crankshaft, of knowledge Since 2010 Keystone has enjoyed capacity and the addition of signifi- camshaft, idler and balance shaft an average compound growth rate cant equipment capacity, primarily sprockets) (Fig. 6), camshaft sensors, C J Kogovsek, Keystone’s President of over 15% annually. “This has been related to its automotive clutch valve actuators and EGR components. and CEO, told Powder Metallurgy driven by launch of several significant assembly business. “We expect “The company will be participating Review, “The Company’s growth is new programmes and the recovery further building expansion of approxi- in four new engine launches over the testament to the soundness of its of the automotive market. Based on mately 3000 m2 in Lewis Run and next two years, all of which have a long held simple belief that success new business received over the past substantial investment in primary displacement of 2.9L or less and all will come as the result of supplying 18 months and an automotive market moulding, sintering and machining have start/stop technology or will be a better product, made a better way, that remains in the 16,000,000 capacity in all three facilities from used in a hybrid propulsion system. 2014 through 2016,” added Kogovsek. Keystone’s sales into these new smaller hybrid/electric systems will “The Company’s growth is testament to Markets for Keystone more than double from 2013 to 2018,” added Stauffer. the soundness of its long held simple Keystone, as with the vast majority “With over 70% of powdered metal of the press and sinter PM industry, belief that success will come as the result parts produced being consumed by is heavily reliant on the automo- the automotive industry, the health, of supplying a better product, made tive sector as its main customer. growth and evolution of the PM Keystone, however, also lists Fig. 7 Keystone is the first company to supply Powder Forged helical pinion industry will be driven by changes a better way, by the best trained and major electrical motor and power gears in this market. The automotive tool manufacturers amongst its motivated workforce” industry challenges it suppliers every so structured, scientific and perva- customers. Powder Forged helical day to provide ever better quality, sive that it’s hard to imagine that a Commenting on the main markets pinion gears by the best trained and motivated vehicle range, Keystone is projecting more productive and cost efficient company that hasn’t been around for Keystone over the next ten years workforce. Keystone’s growth has to grow at average annual rate of processes and to help it achieve its since the 1980s, and hasn’t lived Keystone’s development of the Powder Stauffer told Powder Metallurgy not been the result of mergers and 9% compounded through 2020,” twin goals of fuel economy and noise through the evolution of these stand- Forged helical pinion gear marked a Review, “Automotive will continue acquisitions but of the steady organic stated Mike Stauffer, VP Sales and reduction,” stated Stauffer. ards, could possibly have the depth real breakthrough for the industry. to present the biggest opportunities reinvestment of its profits into devel- Marketing. As fuel prices continue to rise of understanding or the infrastruc- For over twenty years Keystone has and the biggest challenges for the opment of materials and processes and government mandated CAFE ture necessary to fully grasp and supplied Powder Forged pinion gears PM industry in the next ten years. and people deep in experience and Further site expansion planned requirements increase, the US implement them. We work hard to to the automotive sector, primarily With the automotive manufacturers extremely focused on developing new The company’s recent organic automotive industry is pushing ensure we maintain all necessary for use in 4WD transfer case applica- continuing to push for increased products and new ways of producing growth, along with planned growth for smaller, lighter and more fuel power density in their engines and them. The advantages we have as the result of new nine and ten efficient engines and transmissions. transmissions, demand for higher come less from scale than depth of speed transmission business, has The engines are being designed with density, higher strength materials “Keystone’s development of the Powder understanding which we offer to our led to the need for expansion. In 2013 fewer cylinders resulting in fewer will rise. Powder Forged products customers in design of their products the company made a 950 m2 addi- connecting rods, bearing caps, valve Forged helical pinion gear marked a real such as the Powder Forged helical and the ability to rapidly respond to tion to its St Marys facility, as well as seat inserts and guides. pinions are well suited to meet these breakthrough for the industry” “Even with the increased number increasing demands.” of VVT components in these smaller With the automotive sector engines, the overall weight of PM quality certifications and live by these tions. However, in 2012 the company remaining the main market for parts per vehicle will more than guidelines from the advanced product launched its first Powder Forged Keystone, the continued develop- likely decline. Transmissions on the stage through delivery and beyond,” helical pinion gear (Fig. 7). ment of components, either through other hand are being designed to stated Kogovsek. The helical pinion gear transfers design, process or materials, is increase fuel efficiency via increases The automotive industry’s torque and rotational speed between essential for the business. “We in the number of speeds from the demands for productivity and innova- the ring gear and the sun gear. This see the adoption of transmission current five and six speeds to the new tion are widely known throughout the gear is used in the HF 35 Hybrid gears as an exciting growth market. nine and ten speed designs,” stated supply base and Keystone employs Transmission which is assembled However, we believe by using Powder Stauffer. “These new designs tend to productivity improvement teams in into the Lincoln MKZ, Ford C-Max and Forged gears the potential exists have a higher number of PM compo- every facility to constantly look at Ford Fusion hybrid vehicles. The gear for increased power density and nents and, in particular, more gears. current processes and identify ways has to be extremely quiet in operation cost savings by designing a smaller The challenge for the PM industry is to reduce cost and offset inflation. as poor gear geometry will create a transmission box to fully utilise the to continue to drive growth and create “We believe we have been most noisy gear which can easily be heard superior strength of Powder Forged opportunities through innovation, appreciated by automotive customers in a hybrid transmission. gears,” stated Gary Anderson, VP like Powder Forged helical gears and when we demonstrate our under- In 2013 Keystone shipped over Research and Engineering. Powder Forged gears in general.” standing of their need to reduce 400,000 Powder Forged helical pinion In addition to the significant range Supplying the automotive sector weight and noise and participate in gears to Ford for the HF35 transmis- of products produced for transmis- has its own challenges with both the design stage to develop innova- sion. To-date, just under one million sion and transfer case applications, cost and quality playing major roles. tive ways to accomplish these goals,” have now been shipped without any Keystone also supports many engine “The automotive quality regimen is Kogovsek added. field returns. Fig. 6 PM is a proven cost-effective manufacturing process for sprockets systems with products such as

As seen in Fig. 11 the compaction of the powder metal preform is Atomise powder axial, being forged bi-directionally from both the top and bottom. As in Rescreen and blend tool steel manufacturing, the entire alloying elements part is longitudinally forged, including the helical teeth, which results in Press/sinter gear smaller, fewer, and less significant inclusions. Powder Forge “Although it is critical that the powder used in the Powder Forging Machine ID bore & faces process be clean [no inclusions] and moderately compressible, the Carburise, quench & temper ability to successfully manufacture Powder Forged helical pinion gears Secondary operations at production volumes requires very (typically grind) tight controls of several key process parameters,” commented Anderson. Fig. 9 The Powder Forging process Fig. 10 Comparison of a preform (top) Fig. 11 Schematic of the tooling used Fig. 8 The helix angle is Powder Forged to net angle at 1093°C The main challenges Keystone faced were stated as: and finished Powder Forged gear in the Powder Forging process

Property Core Carburised • Weight control: When forging Testing was performed at the 3 Tensile Strength 1310 MPa 189,999 psi 1932 MPa 280,213 psi to 7.82 g/cm , weight control Gear Research Institute of The becomes critical Yield Strength 1070 MPa 155,190 psi 1725 MPa 250,190 psi Pennsylvania State University, • Temperature control: Tempera- USA, (GRI) and Keystone Powdered Hardness HRC 38 HRC 60 ture control is an important Metal Company using GRI’s testing Young’s Modulus 200 MPa 200 MPa element during forging, as this methodology. The following results Table 1 Properties of the Powder Forged helical pinion gear will lead to size variation. Size were reported: variation, in turn, will lead to • Single Tooth Bending Fatigue variation at teeth face grinding (STBF):The STBF for forged Wrought inclusion 500 X Powder Forged inclusion 500 X “With no sacrifice in part Development of the Powder Forged affecting time and clean up areas wrought 4620 is 1372 MPa strength or performance the Powder helical pinion gear • Heat treatment: Control of case (199 ksi) compared to 1435 Fig. 12 The morphology of the forged wrought inclusion (left) compared to a Forged pinion gear offers significant The pinion gear is a helical gear with depth is an important element MPa (208 ksi) for Powder Powder Forged inclusion (right) cost savings compared to conven- a right hand 24.5° helix angle. The to control as variations in case Forged 4620 material and tional wrought steel gears,” stated helix angle is Powder Forged to net depth or lack of enough case 1138 MPa (165 ksi) for forged Anderson. “The Powder Forging angle at 1093°C (2000°F) (Fig. 8). The would affect tooth bending wrought 8620 material process has a raw material utilisa- ID is then machined to make the part fatigue strength tion of 80% (raw material input vs. concentric, the part is then carbur- • Rolling Contact Fatigue (RCF): finished part weight) compared to ised, quenched and tempered to meet • Gear handling: Handling of parts In RCF, the Powder Forged 50% for typical machined gears. In specification. The faces are ground during manufacture is critical 4620 material system had the addition, the energy used for Powder and the teeth are hard finished by to prevent damage to the gear same result as both wrought Forging is 49 K Joules compared to grinding to meet the gear tolerance, teeth with nicks and dents which materials tested (1945 MPa result in scrap parts. Nicks and (282 ksi) vs. 1952 MPa (283 82 K Joules for machined products a normal process also performed on Wrought inclusion 50 X Powder Forged inclusion 50 X resulting in a lower carbon foot- wrought steel gears. The ID is triple dents on the teeth will also affect ksi)) the correct contact of the teeth print. The powder forge process can honed to meet the very tight finish • Grain Size: Using the ASTM Fig. 13 The number of inclusions found in the wrought steel (left) compared to with the mating gear resulting in be lower cost than wrought due to tolerance, ID tolerance, cylindricity E-112 grain size chart, the the Powder Forged material (right) fewer processing steps, less mate- and straightness. increased stress and noise. Powder Forged material rial waste and it consumes less The Powder Forging process route Fig. 12 shows a microstructure of results in a comparable grain STBF Tooth Energy Processing Process RCF (Mpa) energy.” for the production of gears is shown a forged wrought inclusion on the left structure. (Mpa) Grain Size Used Steps “In line with fuel price rises in Fig. 9. Typically, Powder Forging and Powder Forged inclusion on the The benefits of Powder Forging Powder 1435 1945 7 or 8 49 KJ 8 and the increases in government results in a density increase from right. The round morphology of the for the production of helical pinion Forging restrictions the company sees the conventional preform of 10-12%, Powder Forged inclusion compared gears can be seen in Table 2. Wrought an increasing demand for hybrid creating a part virtually at theoretical to the linear (stringer) morphology 1138 1952 7 or 8 82 KJ 9 Keystone concluded that static 8620 vehicles. Based on this shift in the density. A comparison of a preform of the wrought forged inclusion is and dynamic test data supports Wrought market it is estimated that the and finished part is shown in Fig. 10. visible. In Fig. 13 the number of using Powder Forged material and 1435 1952 7 or 8 82 KJ 9 4620 volume on this gear could more The mechanical properties of the inclusions found in the wrought steel processing to produce pinions to than double in the coming years,” Powder Forged helical pinion gear are shown compared to the Powder replace those made from wrought Table 2 Comparison of Powder Forged and wrought materials in the production added Stauffer. are shown in Table 1. Forged material. steel material. of helical pinion gears

continue to take on more design responsibility and provide their customers with higher value added components and assemblies,” stated Stauffer. “The Ford HF35 Planetary Assembly is a perfect example of how to create new opportunities. As originally designed this assembly had only one powdered metal part. Keystone worked with its customer, Ford Motor Company, to optimise the design and drive cost out of the system. Today the HF35 Planetary Assembly has seven powdered metal components, which include a carrier spider, carrier plate, four Powder Forged helical pinions and a pump drive sprocket.” The spider and carrier plate are compacted and then sinter-brazed together before being joined to the shaft using a specially developed method. After precise machining of the carrier, tooling was created to assemble the pinion gears, pinion Fig. 14 The Ford HF35 planetary assembly won the Grand Prize in the bearings, pinion shafts and the Automotive Transmission category at the MPIF’s 2014 Design Excellence washers in a very precise manner. It is Awards (Courtesy MPIF) estimated that cost savings of around 25% were achievable via this route. “With the Powder Forged gears Producing the complete being full density and stronger planetary assembly Outlook than wrought we see one for one replacement opportunities growing In what is believed to be a first Keystone’s commitment to continued substantially, especially when one for an automotive OEM, Keystone technical research and product considers that the full density part manufactures the complete development, as well as its ability to enables the inside diameter to be transmission planetary assembly manufacture products to the highest used as a bearing race, the end that houses the Powder Forged quality, has seen the company achieve great success over the years. The experience and knowledge found The perfect recipe for success. “To capitalise on the growth within the company gives it the flexibility to adapt to the changes within opportunities PM companies must ceramitec 2015 is the sureﬁ re way to give your busi- the automotive sector, leading the continue to take on more design way in producing lighter, stronger ness the competitive edge. Exhibit at this leading responsibility and provide their and more cost effective components. international exhibition and enjoy the beneﬁ ts of a The enthusiasm of its workforce and truly professional forum: strength of the management team customers with higher value added ∙ Full coverage of the ceramics sector. will no doubt ensure it maintains this components and assemblies” success in the coming years. ∙ High-caliber trade audience from around the world. ∙ Professional services for exhibitors. faces of the gear to handle thrust helical gear (Fig. 14). Normally Contact Don’t delay. Sign up today! loads and the teeth to handle loads this is a core commodity and is Michael G Stauffer in excess of conventional wrought usually manufactured in-house at Vice President, Sales and Marketing To register: gears,” commented Anderson. “In the customer’s plant. The planetary Keystone Powdered Metal Company www.ceramitec.de/application most instances, smaller Powder assembly connects to the input shaft 251 State Street Forged gears can replace larger from the engine and supports the St Marys, Pennsylvania wrought gear components and planetary pinion gears. 15857-1697, USA maintain the same or higher load “To capitalise on the growth Tel: +1 814 781 1591 carrying capabilities.” opportunities PM companies must Email: [email protected]

Uniform Rapid Quenching of hammerhead HIP’14: Highlights from the – 500°C/min 11th International Conference Time, 0 The Ultimate Heat sec on Hot Isostatic Pressing Treatment Machine 11

HIP’14, the 11th International Conference on Hot Isostatic Pressing, took place in Stockholm, Sweden, from June 9-13 and attracted an international With Avure’s new Uniform Rapid Quenching (URQ) technology 21 audience to discuss the latest technical and commercial innovations in Hot Isostatic Pressing and Quenching can for the first time be this dynamic sector of Powder Metallurgy. Dr Stephen Mashl, Chairman combined in the same machine. of the International HIP Committee (IHC), reports on event highlights for Powder Metallurgy Review, including winners of the HIP Parts of Excellence 32 Controlled cooling rates up to 3,000°C/min can be achieved competition that offer insight into the commercial application of HIP and the main benefits compared to conventional quenching technology. are: reduced residual stresses, more accurate tolerances and less machining of the heat treated product. 43

Reduced Thermal Stresses 53 Thermal stresses Thermal stresses salt bath (60s) URQ (60s) HIP’14, the latest in the series of of the conference and presents the History of the International triennial international conferences winners in the HIP Parts of Excel- HIP Committee 64 focused on Hot Isostatic Pressing lence Competition. This competition (HIP) technology, was organised by provides a good overview of what is The modern commercial HIP industry 158 MPa 50 MPa the International HIP Committee possible today with advanced HIP is generally seen as originating from (IHC) in conjunction with Jernkon- processing. a research and development effort at HIP Quenching Values toret, the Swedish Steel Producers’ 75 Association. The technical By combining the possibilities of high pressure and programme was structured such temperature control, URQ can offer the market: that it comprised three sessions of invited papers organised by • New possibilities for material development markets, namely oil and gas, power • Heat treatment steps can be included into the HIP cycle 85 generation and aerospace. Inter- spersed between these sessions • Process steps can be removed from the usual process route were nine sessions covering mate- to increase productivity and reduce cost rials produced using HIP, process modelling, and the HIP process. 96 In addition to the technical Please visit industry.avure.com/URQ programme, the IHC organises a competition for HIP Parts of Excel- to change your view on Hot Isostatic Pressing. lence in which companies submit parts that have been manufactured using HIP technology and Avure Technologies is the Global Leader in High Pressure Technology Due to the high pressure, With more than 50 years of experience and expertise, Avure Technologies is unmatched as a solution provider of quenching in a HIP avoids that are felt to display high quality world-class high pressure presses. Avure has an installed base of over 1,700 systems worldwide, including: isostatic thermal stresses, warping and state-of-the-art processing. th presses (hot and cold), sheet metal presses (Flexform), high tonnage ram presses and food presses. All products or cracking of your parts, Fig. 1 The city of Stockholm, Sweden, was host to the 11 International and services leverage our in-depth expertise in delivering the finest high pressure solutions. compared with oil and/or This report provides an overview Conference on Hot Isostatic Pressing Read more on industry.avure.com water quenching.

At the 1991 conference in Osaka, The 2014 Stockholm opening night reception at the Vasa Japan, Professor Mitsue Koizumi conference Museum and a conference dinner at of Ryukoku University suggested Vaxholm Castle. that the two series be combined Returning to Sweden after 27 years, The Programme Committee was into one and that a committee HIP’14 represented the eleventh made up of 23 individuals from nine be assembled for the purpose of in the series focused solely on Hot countries and, led by Adeline Riou of organizing future HIP conferences Isostatic Pressing. With the combina- Erasteel, France, developed an excel- [1]. It was agreed that a conference tion of speakers, attendees, students lent programme with heavy end user every three years was appro- and exhibitors totalling 175, and a participation. Thanks, in part, to the priate and the International HIP programme offering 42 oral pres- efforts of the programme committee Committee was formed to organise entations and 30 posters, this IHC the conference was able to attract this event. Thus, in 1993, the first conference was the largest and most individuals from every market niche in a series of triennial meetings successful IHC event to-date. A local having an interest in Hot Isostatic organised by the IHC began. Dr W organising committee led by Confer- Pressing. A Kaysser of Germany was elected ence Committee Chair Carl-Gustaf It is worth noting that the three as the first Chairman of the IHC in Hjorth, consultant and retired from major markets in which HIP is Fig. 2 Around 175 delegates attended the HIP’14 conference Fig. 3 Freddy Busschaert, Total E&P, France, delivers a 1991. Sandvik, along with Local Organ- frequently used, aerospace, oil & in Stockholm. There were a total of 42 oral presentations and talk describing the oil and gas industry’s experience with Dr Kaysser was succeeded by ising Committee Chair, Gert Nilson gas and power generation, were well 30 posters during the event (Courtesy E Söder, Jernkontoret) HIPed components (Courtesy E Söder, Jernkontoret) Dr Prof L Delaey, Belgium and by of Jernkontoret was made up of represented and each of the three Dr Prof Y Miyamota, Japan. Mr representatives from five companies days of the conference had special 1st International Conference on Isostatic Pressing Battelle Memorial Institute in the John Hebeisen became Chairman having significant business groups sessions devoted to one of these Loughborough, UK 1978 Co-sponsored by Loughborough University of mid-1950s. That effort employed the September 19-21 of the IHC in 2002, served with Dr in Sweden; Avure Technologies, markets. The overall quality of the Technology and Metal Powder Report combination of elevated tempera- Sam Moricca as Co-Chair from Bodycote HIP, Carpenter Products, papers and posters presented at the Stratford-upon Avon, UK 2nd International Conference on Isostatic Pressing ture and isostatic gas pressure was 2005-2008, then was succeeded Erasteel, Sandvik Powder Solutions, conference was very high and together 1982 September 21-23 Metal Powder Report used to clad uranium oxide fuel by Dr Stephen Mashl at HIP’11. as well as Jernkontoret. The venue with the IHC’s HIP Parts of Excel- elements with a zirconium alloy. London, UK 3rd International Conference on Isostatic Pressing The primary purpose of this group was the conference facility at the lence winners the event showcased 1986 During the 1960s and early 1970s November 10-12 Metal Powder Report remains the organisation of the Clarion Hotel Sign in Stockholm. the current state-of-the-art in HIP the process transferred from the triennial HIP conference. Conference events included an technology. 4th International Conference on Isostatic Pressing 1990 Stratford-upon Avon, UK laboratory to the commercial arena Metal Powder Report and in addition to diffusion bonding/ Table 1 The UK HIP Conferences (The ISO Series), 1978-1990 cladding applications, the use of Hot Isostatic Pressing for the elimination of porosity in castings and the Luleå, Sweden HIP: International Conference on Hot Isostatic 1987 consolidation of Powder Metallurgy June 15-17 Pressing materials became practical. Gaithersburg, USA Hot Isostatic Pressing Theory and Applications: The 1989 By the late 1970s and 1980s the June 7-9 Second International Conference technology and the HIP industry Osaka, Japan Hot Isostatic Pressing Theory and Applications: The grew to a level where international 1991 June 10-14 Third International Conference technical conferences were being Hot Isostatic Pressing 1993 held. One series of conferences 1993 Antwerp, Belgium IHC Conference (listed in Table 1) was held in the United Kingdom organised by the HIP ’96 International Conference on Isostatic Pressing 1996 Andover, MA, USA technical journal Metal Powder IHC Conference Report. HIP ’99 International Conference on Isostatic Pressing 1999 Beijing, China A second international confer- IHC Conference ence series, listed in Table 2, HIP ’02 - International Conference on Isostatic began in Luleå, Sweden in 1987. 2002 Moscow, Russia Pressing – An IHC Conference With two competing conference HIP ’05 - International Conference on Isostatic series running between 1986 and 2005 Paris, France H.C. Starck offers a wide variety of special gas and water atomized high-alloyed metal powders, Pressing – An IHC Conference 1990 there were international HIP conferences being held every year such as Fe-, Ni- and Co-based alloys, as well as customized solutions. Huntington Beach, HIP ’08 - International Conference on Isostatic 2008 but one, and, while there was never USA Pressing – An IHC Conference any direct conflict between the two HIP ’11 - International Conference on Isostatic 2011 Kobe, Japan conference series, the technical HIP Pressing – An IHC Conference community was relatively small and HIP ’14 - International Conference on Isostatic the interval between one interna- 2014 Stockholm, Sweden Pressing – An IHC Conference tional technical meeting and the [email protected] www.hcstarck.com next was seen by some as being too Table 2 The Luleå / IHC Series, 1987-2014 short.

HIP Parts of Excellence finished product while the weight of a forged preform was five times greater than that of the finished part [2]. GE Oil competition [MPa] UTS AVG Y0.2% AVG Y0.02% AVG and Gas has established all process and quality control 1300 UTS -3s Y0.2% -3s Y0.02% -3s Continuing a conference tradition parameters and production using the HIP PM approach is 1200 that began in 2002 at the Moscow anticipated to begin in 2015 at a nominal rate of 300 parts 1100 HIP Conference, the IHC organises a per year. The combination of part complexity, part size, HIP Parts of Excellence competition 1000 and dimensional control were factors in this part being as part of the event. Of the candi- 900 named the grand prize winner in the competition. date parts submitted, one part was 800 awarded the Grand Prize while five 700 Dual structure, functionally graded Ni-based superalloy other components were recognised to 600 disks be Parts of Excellence. 0 50 100 150 200 250 [ oC] The All-Russia Institute of Light Metals (VILS) JSC, Moscow, Russia, received an award for their Ni-based Nickel base shrouded impeller Fig. 4 Gabriele Masi, Materials & Processes Principal Engineer for GE Oil and Fig. 7 Ultimate tensile strength, 0.2% yield strength, and superalloy disks. Kazberovitch, et al. [3] describe how GE Oil & Gas, Florence, Italy, together Gas, Florence, Italy (center left) and Dr Federico Iozzelli, Low Temperature 0.02% yield strength as a function of temperature from differences in the local operating conditions within a gas- with Synertech PM, Inc. and LNT PM, Materials Engineering Manager for GE Oil and Gas (center right) receive the 20°C to 250°C for the HIP PM Alloy 625 material used in turbine engine dictate different property requirements for Inc. received the Grand Prize in the Samovar from IHC Awards Chair, Dr Victor Samarov (left) and award certificate this programme disk hub and rim regions. The operating temperature in IHC HIP Parts of Excellence Compe- from IHC Chairman, Dr Stephen Mashl (right), for winning the grand prize in the hub section of the disk does not exceed an average of tition for an Alloy 625M shrouded the IHC HIP Parts of Excellence Competition testing was performed in accordance with NACE TM0177 550°C thus, high ultimate strength properties and low- impeller manufactured for use in and ASTM G39-99 with no failures. Fatigue crack growth cycle fatigue resistance is desirable in the hub section. In centrifugal compressors used in the and fracture toughness thresholds were intermediate contrast, the disk rim material requires high creep resist- oil and gas industry (Fig. 4). Designed between forgings and castings of similar alloy (Fig. 6). ance and should display low fatigue crack growth rates specifically for sour applications, for Elevated temperature tensile and yield strength data are while operating at temperatures of 650-750°C. example, environments where high shown in Fig. 7. To achieve these desirable properties in the specific concentrations of hydrogen sulfide, GE Oil & Gas cited high material utilisation as an regions of the disk, the VILS group developed a tech- carbon dioxide and chlorides create advantage for the HIP PM approach with the weight of the nique which uses two powders to produce nickel-based a particularly aggressive environ- as-HIPed part only weighing 1.1 times the weight of the superalloy disks having a functionally graded, dual ment, the nickel based superalloy component exhibited exceptional dimensional control for such a large Fig. 5 As shown in the left-most CAD image, (a), the shrouded impeller consists PM component. of a number of complex vanes sandwiched between solid surfaces. The part As shown in Fig. 5, the shrouded is difficult to machine from a solid billet. As seen on the right, (b), HIP PM net impeller design, with solid sections shape techniques offer a method by which the complex inner surfaces can covering an array of complex, internal be manufactured to net shape dimensions, leaving only the easily accessed vanes, is a challenging shape to outer surfaces that require machining. The alloy is a NACE-MR0175 compliant manufacture by any method. The material, that exhibits outstanding corrosion properties and resists liquid complexity of the part makes it droplet erosion. HIP and Heat Treatment parameters were optimised for Alloy well suited for production using 625M and sour acid gas applications selective-surface HIP PM net shape techniques. By this method, solid, machined cores made from mild Forging steel are positioned within a capsule Investment casting during the capsule assembly process. PM-HIP 625M Powder fills the remaining voids ] e within the capsule and after HIP, the l c y c

mild steel core and capsule mate- / m rials are removed in an acid bath. [ N d

The as-HIPed superalloy component, / a as shown in Fig. 5b, remains. Heat d treating and an external machining step produce the finished product. Tests performed during product development included: high cycle fatigue, fracture toughness, fatigue <1 MPa m1/2 ∆K [MPa m1 / 2 ] crack growth rate, tensile strength, impact strength, notch sensitivity, Fig. 6 Data from the fatigue crack growth rate assessment of the GE shrouded and sulfide stress corrosion cracking. impeller showed that fatigue crack growth behaviour was intermediate Sulfide stress corrosion cracking between forgings and castings

Fig. 8 A near net shape HIP PM disk (left) was produced from nickel-based VV750P PREP powder such that the the hub and the rim of the disk possessed two distinctly different microstructures Fig. 10 Images show the sheet metal capsule used to produce the 316L stainless steel valve bodies.The image on the left Fig. 9 The micrograph shows the transitional region is an incomplete capsule in which the interior detail is visible. A complete capsule is being inspected on the right Mechanical Properties at 20°C between the fine grained hub section and the coarse UTS 0.2% YS El RA KCU grained disk rim. Microstructural examination showed The valves for this qualification project were made • Enhanced weldability (MPa) (MPa) (%) (%) (kg•m/cm2) that mean grain sizes in the fine-grained and coarse- using a thin-wall capsule, HIP PM near net shape Cast components are often difficult to weld due to the Customer Requirements grained regions of the experimental disk material were technique. Fig. 10 shows images of a HIP capsule in many types of defects that can be present in the micro- 28 and 53 µm respectively. The width of the transition an intermediate and completed state. Fig. 11 shows structure. Furthermore, castings and forgings typically Rim 1470 1078 13 14 24.5 region from fine grained to coarse-grained material was the completed valve and that valve after sectioning. result in very large grain sizes that can create addi- Hub 1519 1127 12 13 24.5 approximately 800 µm Combined, the two Figs illustrate how a sheet metal tional issues in the welding and fabrication processes. container can be fabricated such that internal chambers The homogeneity and fine grain size of PM/HIP parts Transition 1470 1078 13 14 24.5 are produced as part of the process. eliminates many of the conventional weldability issues Achieved Disk region 100 hr. stress- LCF resistance Gandy et al. cite several advantages that HIP PM inherent to either cast or forged components. rupture strength at at 650°C at 2x104 components offer the electric power industry. Rim 1503 1095 16 16.8 33.3 750°C (MPa) cycles (MPa) • Inspectability Rim 750 1050 Hub 1540 1082.5 22.7 21.6 34.8 HIP PM components possess a uniform, homog- AMERICAN ISOSTATIC PRESSES, INC. Transition 1512.5 1072.5 20.5 18.7 - Hub 700 1100 enous microstructure that is very easy to inspect The HIP Industry Innovators in terms of both detection and sizing offering the Table 3 Mechanical properties in various regions of VV750P Table 4 Stress rupture and low cycle fatigue properties in ability to detect extremely small flaw sizes for * HIP - Hot Isostatic Presses alloy dual microstructure disk various regions of VV750P alloy dual microstructure disk critical components. * CIP - Cold Isostatic Presses * Temperatures to 2200 C • Near-Net Shaped (NSS) components * Pressures to 700 MPa structure [4]. Two approaches were 316L Stainless steel PM HIPed tion community for three reasons. * Thermocouple Sales Components produced with PM/HIP tech- used to achieve this type of structure: nuclear valves Firstly, within the US, materials and * New and Used Systems niques can be produced very near final shape, production of a dual structure disk The Electrical Power Research processes utilised to manufacture resulting in reduced component weight, reduced from alloy VV750P powder in which Institute (EPRI), USA, working with pressure retention or high-temper- machining, reduced energy consumption (such structural variation was achieved Synertech PM, Inc., Carpenter ature power plant components are as in melting more material than required), and though the selection of alloy powders Powder Products, and Tyco Flow generally subject to the ASME Boiler reduced waste from post-process machining. having different particle sizes, and Control, manufactured 316L Stain- and Pressure Vessel Code and no the production of a bi-metallic disk less Steel PM HIP Nuclear Valves that code existed for HIP PM materials. • Decreased machining/residual stress having a rim of alloy VV750P and were produced as part of a successful Secondly, the size and shape of Stainless steels and nickel base alloys work bore from VV752P alloy. A 179 kg disk effort to establish ASME Boiler and near-net shaped components have harden during machining. Work hardening not having a diameter of 524 mm, made Pressure Vessel Code Case N-834. only recently reached a point compa- only increases the difficulty in machining, but using two different alloy VV750P The valve bodies were manufactured rable to forged/cast parts. In addition, can also induce residual stresses near the powders, one fine and one coarse, to Tyco Valve drawings and specifica- the compositions/alloys that are of surface of a given component. Residual stresses was submitted to the competi- tions allowing Tyco to independently most interest to the industry have not drive known cracking mechanisms such as tion. Fig. 8 shows an image of the and rigorously evaluate the manufac- been readily available. stress corrosion cracking in stainless steels for disk prior to heat treat and Fig. 9 tured valve bodies. Thirdly, the PM/HIP production nuclear power applications. shows the microstructure in the As stated by Gandy, et al. [5], large route is generally perceived to be • New alloy systems and chemistries transitional region between fine and power generation components have more expensive than traditional Metal powder production is often a flexible coarse grained material in the HIPed traditionally been fabricated using forging and casting routes. However, process in that specific chemistries can be material. The properties of the two established methods including: for stainless steels and nickel-based produced to an individual customer’s require- sections of the VV750P disk are listed casting, rolling, drawing, forging, alloys, material systems where raw ment, multiple powder heats can be blended to 1205 S. Columbus Airport Road in Tables 3 and 4. extrusion, and welding. HIP PM material costs are much higher, PM/ provide a near-exact chemistry and heats can be Columbus, Ohio 43207 components have not been heavily HIP may offer a highly cost effective produced according to need, for example, ranging AIP PH: 1-614-497-3148 used within the power genera- solution for specific applications. in size from hundreds to thousands of pounds. FX: 1-614-497-3407 www.aiphip.com

• Alternate supply route / decreased delivery times For some components long lead-times (of the order of two to five years) are commonly encountered in both the fossil and nuclear power generation sectors. The recent approval of PM/ HIP technologies in the ASME BPV Code will allow utili- Fig. 11 Two images showing the as-HIPed 316L valve body (left) and the same ties to source components valve body that has been sectioned in half as part of the evaluation performed in from an alternate, PM HIP preparation of the ASME Code Case parts supplier. In a situation such as a forced outage due Heat 814520 815111 Y1620B to component failure, the constraint is lead time as Size S31603 (316L) 1892 lbs 1200 lbs 1200 lbs Specification1 lost generation can be valued Product in the millions of dollars a Valve Valve Valve Form day. Thus, even in situations Fig. 12 The powder compaction die (top) used during Fig. 13 The die surface after being taken out of service. the pressing of the ceramic powder employed in the Presumably because of the extremely fine microstructural C 0.030 max 0.013 0.021 0.004 where on a component basis PM-HIP may be more expen- manufacture of the components also shown in the image features, wear on the die interior was very uniform Mn 2.00 max 0.90 0.95 1.41 sive, the improved lead time yielding a five to seven fold increase in die life P 0.045 max 0.014 0.009 0.005 that PM HIP offers is desirable. customer testing. The NSB 63 die inserts were taken out complex borocarbide, and a chromium borocarbide. While • Elimination of rework or S 0.030 max 0.003 0.004 0.005 of service only when die wear had resulted in parts that the distribution of these phases was homogeneous with repair of large cast compo- exceeded dimensional tolerances. As illustrated in Fig. equiaxed grains ranging from approximately one to five Si 1.00 max 0.70 0.80 0.55 nents 13, the insert was observed to maintain its mirror finish microns,EPSI_93x132:Layout closer examination 1 09.09.2011of the material 14:20 in a trans Uhr - Seite 1 Ni 10.0-14.0 12.1 13.2 13.3 The ability to produce homo- throughout production and post–process profilometry of geneous microstructures Cr 16.0-18.0 17.3 17.3 16.87 the insert indicated highly uniform die wear. via HIP PM substantially HIPing NSB 63 powder at 1079°C and 103 MPa for Mo 2.0-3.0 2.55 2.50 2.37 reduces the number of three hours produced a pore-free alloy having a density repairs required in castings. N 0.10 max of 7.59 g/cm3 and an as-HIPed hardness of 63Rc [6]. The In discussions with various properties of the as-HIPed material are listed in Table 7. Others N/A O: 0.010 N/A N/A valve manufacturers, it is The NSB 63 material was able to be used in the as-HIPed 1Specification = ASTM A988/A988M not uncommon for large condition. No post-HIP heat treat was required thus Table 5 Chemical composition of four S31603 (316L) manufactured components cast components to require providing greater process economy and avoiding any prob- between 10 to 50% (by lems with distortion during heat treatment. Isostatic Presses Elongation Reduction volume) repairs to eliminate ProductionCIP: dia 1m,200 MPa ProductionHIP:2000°C,200MPa Temperature Tensile Strength Yield Strength As shown in Fig. 14, the as-HIPed alloy possessed a in 4D of Area casting defects. three phase microstructure comprised of alpha-iron, a (°F) (°C) (ksi) (MPa) (ksi) (MPa) (%) (%) Composition and mechanical prop- 70 21.1 93.4 644.1 47.4 326.9 50.5 73.5 erty data for the 316L valves can be seen in Tables 5 and 6. Melt Point 1141°C 100 37.8 90.4 623.4 46.1 317.9 54.5 75.0 Theoretical Density 7.59 g/cm3 200 93.3 84.5 582.8 41.7 287.6 46.5 74.5 Nanostructured NSB 63 die insert Hardness Vickers1 772 HV The NanoSteel Company, Rhode 300 148.9 79.2 546.2 36.6 252.4 46.5 73.0 Island, USA, received a part of excel- Hardness Rockwell C 63 HRC 400 204.4 76.9 530.3 37.3 257.2 45.0 70.5 lence award for its production of a die Wear Resistance2 (mass loss) 0.120 g 500 260.0 75.5 520.7 33.6 231.7 45.0 71.5 insert manufactured from their NSB 63 powder. One of a family of ferrous- Wear Resistance2 (volume loss) 15.8 mm3 600 315.6 75.0 517.2 31.1 214.5 44.5 70.5 based powders having true nano- Coefficient of Thermal Expansion (200°C) 10.4 μm/m•K 700 371.1 74.8 515.9 30.8 212.4 41.5 66.5 scale microstructural features, dies fabricated from NanoSteel’s NSB 63 Coefficient of Thermal Expansion (1000°C) 13 μm/m•K 800 426.7 74.5 513.7 28.5 196.5 44.5 66.0 powder were used in the compaction Compressive Yield Strength 1868 MPa Engineered Pressure Systems Int. N.V. 900 482.2 73.0 503.3 27.8 191.7 44.5 67.5 of the ceramic powder used to make Walgoedstraat 19, B 9140 Temse, Belgium Compressive Elastic Modulus 265 GPa Tel : +32 (0)3 711 64 24 1000 537.8 72.6 500.6 26.0 179.3 46.5 66.0 the components shown in Fig. 12. NSB 63 out-performed the previ- 1Extrapolated from HRC [email protected] www.epsi-highpressure.com 2 Table 6 Elevated temperature, tensile test results for one 316L stainless steel ously used AISI A11 tool steel by ASTM G65-04 Procedure A - 6,000 Cycles For customers in North America, please contact : EPSI-Haverhill, MA Tel : + 1 978 469 82 80 valve body manufactured during this project lasting five to seven times longer in Table 7 Consolidated alloy (HIP) properties

Forged austenitic valve steel substrate (SNCrW)

PM HIP H. T. corrosion & wear resistant seat coating Intermediate layer (PM 316L)

PM HIP H. T. corrosion resistan coating (Ni49Cr1Nb) Fig. 14 A micrograph of HIPed NSB 63™ alloy taken on an SEM Fig. 15. A bright field TEM micrograph of a NSB63™ in backscatter mode. At this magnification this material displays sample showing a nanocrystalline sub-structure Fig. 17 Schematic showing the intricate arrangement a homogeneous distribution of primary phases. The light gray having an average feature size of approximately 5 nm of four different materials on the combustion face and phase is the complex metal borocarbide, medium gray is alpha- valve seat area of the marine diesel valve stem iron, and the dark gray is the chromium borocarbide. When this structure is examined at even higher magnifications on a TEM, a Fig. 19 Finished quad-metal valves ready for installation nanoscale sub-structure becomes visible

mission electron microscope under bright field conditions, such as that Material C Ni Cr Fe Nb Other in Fig. 15, reveals a much finer substructure consisting of evenly SNCrW (substrate) 0.25 10 20 Bal. - 2(W)

dispersed nano-crystals nominally m PM Ni49Cr1Nb (disc m 5 nm in size. 0.02 Bal. 49.5 - 1.25 - 8 coating) 6 3 PM Ni40Cr3.5NbTi 0.02 Bal. 40 - 3.5 - Hollow support for aerospace high (seat coating) pressure compressor PM 316L (interme- 0.025 12 17.5 Bal. - 2.5(Mo) CMK Joint-Stock Company, diate layer) Stupino, Moscow, was recognised Fig. 18 A welder seals the capsule that, attached to the Table 9 Chemical composition of the materials used in the for the production of the hollow 660 mm support for the high-pressure valve stem substrate, surrounds the multiple materials quad-metal exhaust valve spindle within the capsule compressor used in IL 96 300, Fig. 16 The hollow support component used in the high-pressure compressor SU-27, SU-30, SU-35, I176, MIG 29, section of multiple Russian gas-turbine engines TU-204 aircraft. This part has been manufac- layer of 316L stainless steel is used the parts and they are expected to EPRI’s 316L valves represent tured using other alloys since 1982. Ni-based Operating as an intermediate layer separating continue in operation for many thou- classic stainless steel HIP PM alloy Mo W Al Ti Nb This part is now being made from Temperature the SNCrW substrate from the seat sands of hours [7]. near net shapes produced using a Alloy and face materials. All materials thin-wall capsule technique. The the Ni-based alloy 741 NP powder 741NP 3.5 – 4.2 5.2 – 5.9 4.8 – 5.4 1.6 – 2.0 2.4 – 2.8 Up to 750°C in a HIP + forging process that, in except the SNCrW substrate are Best capabilities of Hot Isostatic NanoSteel compaction die insert replacing Alloy 698 has increased Table 8 Alloy element ranges and maximum operating temperature for Alloy HIPed Powder Metallurgy materials Pressing represents a significant advance operational life by a factor of two. 741 NP applied using a proprietary approach. Combined as a group these six parts in part performance, driven by a In the Alloy 741NP form, this part The final sealing of the capsule present many of the best capa- paradigm shift in powder making. is the second new PM product line PM HIP quad-metal exhaust valve simultaneously. In this part, the valve material to the valve stem is shown in bilities of Hot Isostatic Pressing. CMK’s aerospace compressor installed since 2013. spindle stem that serves as a substrate is Fig. 18. The large size of these parts The selective surface net shape part provides clear evidence of how The particle size distribution of The PM HIP Quad-Metal Exhaust Valve made of the austenitic stainless steel is evident. shrouded impeller developed by GE a HIPed and forged PM material can the powder used in production is Spindle manufactured by Sandvik alloy, SNCrW. As shown schematically The nominal composition of the Oil and Gas shows the high level be used in a demanding aerospace either 50 – 100 µm, 50 – 140 µm or Powder Solutions, Surahammar, in Fig. 17, a HIPed PM nickel-based various alloys is shown in Table 9. of dimensional control that can be application and finally, the Sandvik made to customer specification. Sweden, for use in large, 2-stroke superalloy Ni49Cr1Nb is used on the Fig. 19 shows the three spindles that attained with this process. The dual- quad-metal exhaust valve shows how As shown in Fig. 16, the part has marine diesel engines manufactured valve face to address the corrosive have been in operation for approxi- structure, graded, two region gas complex combinations of powders overall dimensions of 660 mm in by MAN Diesel A/S is an outstanding environment within the combustion mately one year. The valves are turbine disk offered by VILS shows and solids can be combined to length x 368 mm maximum diam- example of how the HIP process can chamber. Ni40Cr3.5NbTi is used in the removed from the engine periodi- how powder type and process control produce a single part from multiple eter. Chemical composition data for be used to both fabricate shapes valve seat area in order to provide both cally and inspected for evidence of can be used to control microstruc- alloys, allowing varied properties in this alloy are listed in Table 8. and diffusion bond multiple alloys wear and corrosion resistance, and a corrosion and cracks. To date, the ture and thus control properties on a various regions of a large exhaust inspections have found no faults in local scale within a single part. valve.

64 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Autumn / Fall 2014 Powder Metallurgy Review 65 MIM2015_ad_A4_Layout 1 8/21/2014 8:50 AM Page 1

References International Conference on Injection Molding of Metals, Ceramics and Carbides [1] Private Communication with John C Hebeisen. FEBRUARY 23–25 • SHERATON TAMPA RIVERWALK [2] G Masi, P Stella, M Giannozzi, F 5 TAMPA, FL Iozzelli, Perspectives of the Applica- tion of High Strength Nickel Base Alloys by Hip in Rotating Equipment for Oil & Gas Industry, in Proceed- ings of HIP ’14: 11th International Conference on Hot Isostatic Fig. 20 Surfaces of VV752P high-strength Ni-base superalloy powder from two Make plans to attend Pressing, 9-13 June, Stockholm, size fractions. A - 70 μm powder particle is shown on the left while a - 115 Sweden, pp. 28-41. μm diameter powder particle is on the right. Magnification is equal and the [3] A Kazberovich, G Garibov, N variation in dendrite size and arm spacing is apparent the only international Grits, D Yegorov, N Ryzhova, P/M VVP-Class Ni-base Superalloy 2.80 Disks with a Dual Structure and metal and powder

m Functionally Gradient Properties µ

r Manufactured by Direct HIP, in

e 2.30 t

e Proceedings of HIP ’14: 11th Inter- injection molding m

a national Conference on Hot Isostatic r 1.80 a p

Pressing, 9-13 June, Stockholm, c

ti event of the year! i Sweden, pp. 278-287. r 1.30 d

n [4] G S Garibov, N M Grits, JSC e

D All-Russia Institute of Light Alloys 0.80 (VILS), Moscow, Russia, Develop- 30 50 70 90 110 130 150 170 MIM2015 CONFERENCE Powder size, µm ment Prospects of Disk Aircraft Materials Produced via the Powder (February 23–25) Fig. 21 Dendritic parameter versus powder particle size. The effect of Metallurgy Technique and Direct variations in cooling and thus solidification rate on the particles dendrite HIPing, in Proceedings of HIP ’14: A two-day event featuring presentations and a characteristics are apparent 11th International Conference on keynote luncheon Hot Isostatic Pressing, 9-13 June, • Advances in Component Uniformity HIP’14 Best Poster Award The 2017 International HIP Stockholm, Sweden, pp. 278-287. • Part Selection—Best Practices conference [5] D W Gandy, J Siefert, L Lherbier, The Best Poster Award went to Dr D Novotnak, PM-HIP Research, • Leading Process Trends Alexey V Vostrikov and Prof Genrikh This series of international HIP Applications, and Technology Gaps • Numerous Case Studies S Garibov from the All-Russia conferences, ongoing since 1987 and for the Electric Power Industry, in • Tabletop Exhibition & Networking Reception with Institute of Light Alloys (VILS) in taking place every three years since Proceedings of HIP ’14: 11th Inter- Representatives from Many of the Leading Moscow, Russia, for their poster 1993, remains the only international national Conference on Hot Isostatic Companies in the Field entitled Investigation in the Field of event where Hot Isostatic Pressing Pressing, 9-13 June, Stockholm, Physico-Mechanical Properties and a technology is the sole focus of the Sweden, pp. 130-150. ...and Much More! Structure of New Ni-Base Superalloy event. These conferences offer an [6] S J Mashl, H K Lemke, P E Mack, Powder. opportunity to become acquainted B D Merkle, A V Sergueeva, D J The poster summarised an exten- with many of the major companies, Branagan, HIP Processing of Nano- sive analysis correlating variations researchers and end users in a single Structured Ferrous Alloys: Opportu- Optional One-Day Powder Injection Molding in particle size with changes in the conference environment. At the IHC nities Provided By a New and Novel Tutorial Precedes Conference (February 23) physical and mechanical proper- meeting in Stockholm it was decided Microstructure, in Proceedings of ties of PREP atomised VV752P high that the next event will be HIP’17 HIP ’14: 11th International Confer- Taught by Randall M. German, FAPMI strength Ni-base superalloy powder. in Sydney, Australia with Dr Sam ence on Hot Isostatic Pressing, world-renowned PIM expert This conference is sponsored by the Variations in solidification structure, Morrica of ANSTO and Prof Xinhua 9-13 June, Stockholm, Sweden, pp. An ideal way to acquire a solid grounding in powder Metal Injection Molding Association, non-metallic inclusions, particle Wu of Monash taking on the lead for 170-179. injection molding technology in a short period of time a trade association of the shape, dendrite size, porosity, and preliminary organisation. [7] M Östlund, T Berglund, Advanced Metal Powder Industries Federation • Introduction to the manufacturing process carbide phases were examined. SEM PM HIP Compound Products and micrographs showing the differ- • Definition of what is a viable PIM or MIM component Author Prototypes, in Proceedings of HIP ence in dendrite size are apparent in ’14: 11th International Confer- • Materials selection and expectations Fig. 20. Fig. 21 displays the rela- Dr Stephen J Mashl ence on Hot Isostatic Pressing, • Review of the economic advantages of the process tionship between dendrite size and Z-Met, Inc. 9-13 June, Stockholm, Sweden, pp. powder particle size. Email: [email protected] 406-422.

Visit mim2015.org or mimaweb.org for complete program details and registration information

66 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Autumn / Fall 2014 Powder Metallurgy Review 67 | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email | Hardmetal standards european powder metallurgy association Powder Metallurgy Standards: International Hardmetals for cutting applications, wear parts and Congress & Exhibition structural applications 4 - 7 October 2015 In the Winter 2013 issue of Powder Metallurgy Review (Vol. 2 No. 4) Reims Congress Centre, Reims, France Dr Brian James reviewed Powder Metallurgy industry standards with a focus on ferrous structural components. In this, our second report on PM standards, Dr Bryan Roebuck and Eric Bennett from the UK’s National Physical Laboratory focus on the importance of standards in the hardmetals industry, a sector of PM that is estimated to account for around 50% of global PM production by value. As the authors highlight, there is still further work to be undertaken by the standards community in relation to this unique class of materials.

Hardmetal is the term used to collate Table 1 it is worth considering the listed first, followed by a number of a group of hard, wear-resistant various attributes of hardmetals that items that have yet to be addressed materials based on the carbides and/ contribute to the ubiquity of this class by the standards community. It is or nitrides of the elements tungsten, of materials. Those attributes that also worth noting that ASTM, through titanium, tantalum, molybdenum, have associated ISO standards are International Committee B09.06, niobium, vanadium and chromium, bonded with a transition metal or metal alloy based on cobalt, nickel or iron. The range of application covers cutting tools for metals, composites, plastics and natural materials (e.g. shaping wood); mining minerals and Images courtesy of © Carmen Moya 2012 hole drilling (for example in the oil and gas and tunnelling industries) (Fig. 1). Hardmetals are also used as structural and wear parts across most engineering sectors in applications such as extrusion and forming dies, seal rings, rolls. Globally, around 50% by value of the Powder Metallurgy (PM) industry supports hardmetal activities, around $30 billion in total. Before discussing in detail the Fig. 1 A selection of indexable milling inserts and cutter bodies (Courtesy relevant ISO standards listed in Kennametal Inc)

Hardmetals - Physical Test Methods Hardmetals – Chemical Test Methods also has a comprehensive suite of but if specific properties (i.e. prop- ured values. Usually it is less than the hardmetal standards developed over erties normalised per unit weight) compressive strength, typically 2-4 Code Title Code Title many years in North America and are required it is a disadvantage kN/mm2, but still much stronger than ISO 4489:1978 Sintered hardmetals – Sampling and ISO 3909:1976 Determination of cobalt – Potentiometric these are listed in Table 2. It is also [ISO 3369]. many other materials. Processing testing method important to state that this review route is very important. HIPing or ISO 4884:1978 Hardmetals – Sampling and testing of ISO 4501:1978 Hardmetals – Determination of titanium – does not discuss the various issues Hardness Sinter-HIP processing is required for powders using sintered testpieces Photometric peroxide method around geometries and specifica- Sometimes this is measured using a highest values of strength [ISO 3327]. ISO 4505:1978 Hardmetal – Metallographic determina- ISO 4503:1978 Hardmetals – Determination of contents of tions for hardmetal cutting tool Vickers test (HV), sometimes by the tion of porosity and uncombined carbon metallic elements by X-ray fluorescence – inserts that are addressed by ISO Rockwell test (HRA). It can easily be Fracture toughness Fusion method TC29 Committee on Small Tools. varied between 1000-2000 HV30 by This property is hard to measure ISO 4506:1979 Hardmetals – Compression test ISO 4883:1978 Hardmetals – Determination of contents of The attributes of hardmetals can be changing metal phase content and due to difficulties in introducing metallic elements by X-ray fluorescence – described as: hard material grain size. Like many cracks with a known geometry. Solution method other properties of hardmetal there is Typical values of plane strain fracture ISO 3738-1:1982 Hardmetals – Rockwell hardness test ISO 7627-1:1983 Hardmetals – Chemical analysis by flame Stiffness the flexibility to design specific hard- toughness lie in the range 7-25 MN/ (scale A) – Part 1: Test method atomic absorption spectrometry – Part 1: Hardmetals are one of the stiffest ness values by changing composition. m1.5. These values are much higher General requirements materials known, after diamond, with Hardmetals are as hard at the higher than for similar hard materials like ISO 3878:1983 Hardmetal – Vickers hardness test ISO 7627-2:1983 Hardmetals – Chemical analysis by flame a Young’s modulus about three times end as most ceramic materials yet ceramics which have a fracture atomic absorption spectrometry – Part that of steel and six times that of much tougher [ISO 3878; ISO 3738]. toughness of about 2-8 MN/m1.5 . 2: Determination of calcium, potassium, aluminium [ISO 3312]. For hardmetals a modified indenta- magnesium and sodium in contents from Compressive strength tion toughness test (Palmqvist) is 0.001 to 0.02% (m/m) Density Compressive strength values of 4-8 frequently used [ISO 28079]. ISO 3312:1987 Sintered metal materials and hardmetals ISO 7627-3:1983 Hardmetals - Chemical analysis by flame Hardmetals are very dense if they kN/mm2 make hardmetals one of the – Determination of Young modulus atomic spectrometry – Part 3: Determina- contain significant amounts of WC; strongest materials available, witness Abrasion and erosion resistance tion of cobalt, iron, manganese and nickel up to 15 Mg/m3 or slightly higher is their use in diamond manufacture In severe abrasion and erosion in contents from 0.01 to 0.5% (m/m). possible. Lower densities down to as anvils and in hot rolls for metallic environments hardmetals are one of ISO 3738-2:1988 Hardmetals – Rockwell hardness test ISO 7627-4:1983 Hardmetals – Chemical analysis by flame 4-5 Mg/m3 can be tailored by using materials [ISO 4506]. the most wear resistant materials (scale A) – Part 2: Preparation and cali- atomic spectrometry – Part 4: Determina- higher Co contents or additions of available. This is because they have bration of standard test blocks tion of molybdenum, titanium and vana- cubic carbides and carbonitrides Tensile strength a unique combination of strength, dium in contents from 0.01 to 0.5% (m/m). for the hard phase. The high density Usually measured in a bend test. hardness and fracture toughness ISO 3369:2006 Impermeable sintered metal materials ISO 7627-5:1983 Hardmetals - Chemical analysis by flame endows hardmetal with a very satis- Surface condition (grinding stresses) compared with other hard materials and hardmetals – Determination of atomic absorption spectrometry – Part fying feel when handling products can have a significant effect on meas- [ISO 28080]. density 5: Determination of cobalt, manganese, molybdenum, nickel, titanium and vanadium in contents from 0.5 to 2% (m/m) Number Year Title ISO 4499-1:2008 Hardmetals – Metallographic determina- ISO 7627-6:1985 Hardmetals – Chemical analysis by flame tion of microstructure – Part 1: Photomi- atomic spectrometry – Part 6: Determina- ASTM E9-09 2009 Standard Test Methods of Compression Testing of Metallic Materials at Room Temperature crographs and description tion of Chromium in Contents from 0.01 to ASTM B406-96 2010 Standard Test Method for Transverse Rupture Strength of Cemented Carbides 2% (m/m) ISO 4499-2:2008 Hardmetals – Metallographic determina- ISO 11873:2005 Hardmetals – Determination of sulfur and ASTM B294-10 2010 Standard Test Method for Hardness Testing of Cemented Carbides tion of microstructure – Part 2: Measure- carbon contents in cobalt metal powders – ment of grain size Infrared detection method ASTM B276-05 2010 Standard Test Method for Apparent Porosity in Cemented Carbides ISO 3327:2009 Hardmetals – Determination of transverse ISO 11877:2008 Hardmetals – Determination of silicon in ASTM B657-11 2011 Standard Guide for Metallographic Identification of Microstructure in Cemented Carbides rupture strength cobalt metal powders – Photometric method ISO 28079:2009 Hardmetals – Palmqvist toughness test ISO 17352:2008 Hardmetals – Determination of silicon ASTM B771-11e1 2011 Standard Test Method for Short Rod Fracture Toughness of Cemented Carbides in cobalt metal powders using graphite- Standard Test Method for Rating Grain Size and Frequency of Abnormally Large Grains in furnace atomic absorption ASTM B930-03 2012 Cemented Tungsten Carbides (Hardmetals) ISO 22394:2010 Hardmetals – Knoop hardness test ISO 3907:2009 Hardmetals – Determination of total carbon – Gravimetric method ASTM B665-08 2012 Standard Guide for Metallographic Sample Preparation of Cemented Tungsten Carbides

ISO 28080:2011 Hardmetals – Abrasion tests for ISO 3908:2009 Hardmetals – Determination of insoluble ASTM B887-12 2012 Standard Test Method for Determination of Coercivity (Hcs) of Cemented Carbides hardmetals (free) carbon – Gravimetric method ISO 3326:2013 Hardmetals – Determination of (the ISO 26482:2010 Hardmetals – Determination of lead and ASTM B886-12 2012 Standard Test Method for Determination of Magnetic Saturation (Ms) of Cemented Carbides magnetization) coercivity cadmium content Standard Test Method for Determination of Metallic Constituents of Tungsten Alloys and Tungsten ASTM B890-07 2012 ISO 11876:2010 Hardmetals – Determination of calcium, Hardmetals by X-Ray Fluorescence Spectrometry copper, iron, potassium, magnesium, Standard Test Method for Density of Powder Metallurgy (PM) Materials Containing Less Than Two ASTM B311-13 2013 manganese, sodium, nickel and zinc in Percent Porosity cobalt metal powders – Flame atomic absorption spectrometric method ASTM B611-13 2013 Standard Test Method for Determining the High Stress Abrasion Resistance of Hard Materials

Table 1 ISO Test Methods for Hardmetals Table 2 ASTM Cemented Carbide Standard Test Methods: B09.06

Electrical and magnetic Surface finish Edge retention and sharpness to 20% higher than those obtained properties Hardmetal can take a superb mirror The fine scale of the microstruc- using Type A testpieces, depending Hardmetals usually have transition finish, a consequence of its defect- ture and the high strength of the on the material tested and provided metal binder phases and conse- free fine-scale structure. It has a hardmetal enables very sharp edges that they have the same surface quently are slightly ferromag- deep grey lustre which is particularly and corners to be manufactured conditions. The repeatability is netic, with coercive force values attractive [No standards]. which have myriad uses in cutting similar for all types of testpiece. Type between 5-30 kA/m, depending on and shaping processes (cutting C testpieces give strength values the binder-phase content. Non- Coefficient of friction paper, wood and glass, for example) which are about 5%-10% higher magnetic hardmetals can be made Hardmetals have a relatively low [No standards]. than Type B specimens whereas the using Ni or alloy binder-phases as coefficient of friction, about 0.2, in increase of the strength values are an alternative to the more usual unlubricated tests in contact with Corrosion resistance material related. cobalt. Electrical conductivity is steel, as compared with typical steel Corrosion resistance in non-acids The method of surface prepara- good with values of resistivity in the against steel values of about 0.4. is excellent for all hardmetals. tion of the testpieces is important range 150-250 nΩm. Additions of There are few systematic data of the However, if a cobalt binder phase is and should be controlled to ensure cubic carbides generally lower the effects of surface roughness, compo- used they can be prone to dissolution that consistent results are obtained. conductivity [some standards for sition variations and temperature in even mildly acidic environments. Type A and Type B testpieces should magnetic properties – ISO 3326]. effects [No standards]. This can be mitigated by using be ground on the four faces parallel Ni-base or alloy binder-phases which to the length with a resin-bonded Fatigue strength Coatings are inherently corrosion resistant [No diamond wheel using plenty of There are limited data available to Hardmetals easily take a variety of standards]. coolant. No pass should exceed judge properties but hardmetals coatings, e.g. electroless, electro- 0.01 mm and all grinding marks Fig. 2 Orientation coloured image of WC grains demonstrating intercept are likely to be quite good in the plate, vapour or spray deposited. Thermal expansion and conductivity need to be parallel to the length. The measurements absence of strength-limiting Both wear resistance and cosmetic The thermal conductivity of standard amount taken off each face is recom- Type Length Width/Diameter Height defects, as this property usually coatings of many types are cheap and WC/Co hardmetals is about twice mended to be not less than 0.1 mm correlates with strength. Currently effective [No standards]. as high as that of high speed steel. and the face surface roughness is A 35 ± 1 5 ±0.25 5 ± 0.25 it is high priority in research [No Both conductivity and expansion can Ra ≤ 0.4 µm. The four long edges are B 20 ±1 6.5 ± 0.25 5.25 ± 0.25 standards]. Shape be tailored by changing the volume also chamfered to 0.15 mm to 0.2 mm Because hardmetals are manufac- fraction of binder-phase and type of at an angle of 45°. Type C testpieces C 25 ± 5 3.3 ± 0.5 - High temperature strength tured by a Powder Metallurgy route carbide/carbonitride hard phase [No are centreless ground to a surface Table 3 Dimensions of 3 Pt transverse rupture strength test pieces (mm) Very good though sensitive to mass production technologies are standards]. roughness of Ra ≤ 0.4 µm. It must be oxidation. Decreases steadily with possible. However, post-manufacture noted that it is also permitted to use and WC/Cubic Carbide Based the microstructure of hardmetals, increasing temperature. There is a shape changes can be expensive Recent developments testpieces in the as-sintered condi- strong asymmetry between prop- if extensive diamond grinding is tion. Such testpieces have a chamfer Hardmetals such as defects and cobalt lakes. An erties in tension and compression. required [No standards]. Table 1 indicates that from 2006 of 0.4 mm to 0.5 mm at an angle of • Part 4: Characterisation of important part of the new standard Sensitive to choice of hard phase. onwards the committee ISO TC119/ 45°, made before sintering to avoid Porosity, Carbon Defects and is the categorisation terminology Cubic carbide additions such as Dimensional stability SC4 has been quite active with flash. Bend strength results from Eta-phase content. of hardmetal structure by the hard particle grain size in the sintered (Ta,Nb)C and (Ta,Ti)C increase Their use as high quality slip gauges new and revised standards being as-sintered testpieces are gener- • Part 5: Characterisation and products. Following discussion in the elevated temperature strength indicates exceptional dimensional issued. The rationale and primary ally significantly lower than those for measurement of miscellaneous hardmetal community, Table 4 is the significantly [No standards]. stability, provided grinding stresses characteristics where there have ground testpieces due to the pres- microstructural features. are stress-relieved. The microstruc- been significant changes, such as ence of lower strength surface related type of table recommended. Low temperatures tures are inherently stable since they in the Transverse Rupture Strength, features and no compressive residual ISO 4499-1, together with Grain sizes are measured by Hardmetals retain a good combina- are formed by an equilibrium process Microstructure, Toughness and Abra- stresses from grinding. ISO 4499-2, cancels and replaces the mean linear intercept method tion of properties at temperatures at very high temperatures and are sion test standards are discussed in ISO 4499:1978, which has been described in ISO 4499 and the uncer- down to as low as that of liquid cooled to room temperature relatively outline as follows: Microstructure technically revised. In ISO 4499-2, tainty associated with the measure- nitrogen. Hardness increases by slowly [No standards]. The standard for microstructure a new section has been added for ment of linear intercept grain size is about 20-30% with a concomitant Transverse Rupture Strength characterisation is ISO 4499 and the quantitative measurement of about 10% if typically 200-300 grains decrease in fracture toughness [No Joining Originally the Transverse Rupture this has been revised and updated the WC grain size of hardmetals. are counted (Fig. 2). standards]. Brazing is relatively straightforward Test method allowed two rectan- with significant new sections added. ISO 4499-3 is an additional part that Part 3 of ISO 4499 provides as hardmetals are readily wetted gular testpiece geometries to be ISO 4499 will eventually consist of the deals with the microstructures of guidelines for the measurement of Impact strength if clean. However, care has to be used; Types A and B. The Standards five following parts, under the general hardmetals containing cubic carbides microstructural features in Ti(C,N) Not well understood but is probably taken to minimise thermal residual Committee sponsored an interna- title Hardmetals - Metallographic and cermets, Ti (C, N)-based based hardmetals and WC/Co related to tensile strength and stresses because the thermal expan- tional round robin to examine various determination of microstructure: hardmetals. ISO 4499-4 is a further hardmetals that contain additional new section that adds the detection cubic carbides. A cubic carbide phase fracture toughness. Some compa- sion coefficient is quite low, about aspects of this three point flexure test • Part 1: Photomicrographs and and quantification of eta-phase to is defined as a carbide having a cubic nies have used metal test methods, half that of high speed steel. Welding [2,3,4] and as a result the standard description i.e. miniature Charpy-type tests to is not possible but adhesives can be was modified to allow tests on cylin- the previous ISO 4505:1978 for the lattice, such as, for example, TiC or • Part 2: Measurement of WC assess mechanical response [No used in some circumstances if care drical shapes;Type C (Table 3). determination of porosity and carbon TaC, and which usually also contains grain size standards]. is taken with surface preparation [No In general, Type B testpieces give defects. ISO 4499-5 is also a new W in solid solution after sintering. standards]. strength values which are about 10% • Part 3: Measurement of micro- section that addresses the descrip- These materials typically contain structural features in Ti(C,N) tion of miscellaneous features in hard phases that have grains with

Grain size German nomenclature English nomenclature range of values for typical WC/Co A specific ISO Standard for the ness value obtained by measuring tions participated, either by corre- hardmetals is from 7 MN.m-3/2 to 25 plain strain fracture toughness of the crack lengths at the corners of a spondence, supply of materials or by < 0.2 μm Nano Nano MN.m-3/2. There is a general inverse hardmetals has not been written to Vickers indentation. It can be evalu- conducting tests. Eight organisations 0.2 - 0.5 μm Ultrafein Ultrafine trend of hardness against fracture date, primarily because of the diffi- ated by making indentations either at were able to complete Palmqvist toughness. When applied unqualified culty of introducing stable precracks a single load, usually 30 kgf, or from tests. Good statistics were obtained 0.5 - 0.8 μm Feinst Submicron to hardmetals, the phase “tough- into these tough but hard materials. the inverse of the slope of a plot of on the Palmqvist data that enabled a 0.8 - 1.3 μm Fein Fine ness” can have several meanings: However, Palmqvist tests for tough- crack length against load for a range quantitative assessment of uncertain- a) Plane-strain fracture toughness are widely used because of their of applied loads. For hardmetals, ties to be performed for this relatively 1.3 - 2.5 μm Mittel Medium -3/2 perceived apparent simplicity (Fig. 3). the crack depth profile is normally of simple test. Single-edge precracked ness, Klc, in MN.m , is a value 2.5 - 6.0 μm Grob Coarse obtained from tests on specimens Cracks are formed at the corners the Palmqvist type, i.e. independent beam data was thought to be closest with appropriate geometries of Vickers hardness indentations shallow arcs emanating from each to the true value, and the mean >6.0 μm Extragrob Extracoarse for plane-strain conditions and and these can be used to calcu- indentation corner. The measurement values from the Palmqvist test data late a nominal surface toughness of surface crack length is, however, compared reasonably well with these Table 4 Terminology for grain size containing a well-defined geometry of crack. There is no ISO value. This value is sensitive to the open to operator error. It is widely results. However, care was needed in a core/rim structure. This part of of these microstructural features standard method for hardmetals method of measurement and to the recognised that test surfaces have to testpiece preparation to ensure a good ISO 4499 essentially covers materials together with the measurement of and different organisations use method of surface preparation of the be carefully prepared to remove the correlation between data from the types and phases to be measured, porosity levels. Porosity is important different test methods for intro- sample. The International Standard, effects of residual surfaces stresses. Palmqvist tests and the single-edge preparation methods to highlight since these materials are manufac- ducing the precrack. ASTM has ISO 28079, has been developed to The test also has a poor fracture- precracked beam results. differences between conventional tured by a Powder Metallurgy route a specific method for measuring outline good practice to minimise mechanics pedigree because of WC/Co hardmetals and materials and although the technique of liquid the Short Rod fracture tough- uncertainties due to testpiece the uncertainties associated with Abrasion containing cubic phases, and linear phase sintering, often under an ness (ASTM B771-11e1) which is preparation and loading issues. One residual stresses introduced by the Abrasion wear is not a measure analysis techniques to acquire suffi- applied pressure (SinterHIP), is used thought to give values equivalent advantage of the Palmqvist method indentation. of the wear characteristics of cient statistically meaningful data for to consolidate the multiphase struc- to Plain Strain methods. is that parallel measurements are ISO 28079 for Palmqvist toughness hardmetals under all conditions, phase quantification including repre- ture low levels of porosity can arise in made of sample hardness, which is is based on Good Practice Guide for and should not be misinterpreted as b) Strain-energy release rate (or sentative average values. It is also some instances and affect properties required for quality-control purposes. the Measurement of Palmqvist Tough- indicating wear when hardmetals are work of fracture), G, is an alter- The crack length, and thus toughness published by the UK National used for tooling processes, such as native expression for toughness, ness measurements, do not there- Physical Laboratory in 1998. Good cutting and milling. It does, however, often obtained by converting “ISO 4499 parts 1-4 describe the main fore require much more effort and practice is recommended to minimise show the difference in resistance to plane-strain toughness, K, to G can yield equally useful material levels of uncertainty in the measure- abrasive use for different carbide (i.e. G = K2/E(1 - 2), where E is microstructural aspects of hardmetals ν characterisation data, provided the ment process. The procedure has compositions and the methods Young’s modulus and is Pois- ν measurements are obtained carefully been validated through underpinning can be used as practical tests or such as hard phase size, but there son’s ratio. G has units of J.m-2. in line with the methods proposed in technical work within the VAMAS as research methods for material Again, there is no ISO standard are other important features of their this ISO Standard. framework [5,6,7]. An interlaboratory discrimination (Fig. 4). method. structure that can have a significant There is a considerable body of exercise was conducted to generate This new International Standard, c) Palmqvist toughness, W, is a published information on Palmqvist underpinning technical information ISO 28080, provides new and effect on properties” value obtained by measuring the toughness tests for hardmetals. on toughness tests for hardmetals. improved methods for testing total length of cracks emanating Palmqvist toughness, W, is a tough- More than ten industrial organisa- the abrasion characteristics of intended for measuring the phase such as density and strength. from the four corners of a size and distribution by the linear ISO 4499 parts 1-4 describe the Vickers hardness indentation. intercept technique. main microstructural aspects of For a given indentation load, the In standard WC/Co hardmetals the hardmetals such as hard phase shorter the crack, the tougher chemistry and density are generally size, but there are other important is the hardmetal. ISO standard controlled so that only two phases features of their structure that can 28079 follows this procedure. WC and Co are present. The Co phase have a significant effect on proper- d) Finally, toughness is also is an alloy and contains some W and ties, such as defects (miscellaneous widely used, in a loose sense, to C in solid solution. The WC phase is slits, cracked inclusions) or hetero- describe the empirical rela- stoichiometric. If the composition geneities in phase distribution (cobalt tion between perceived resist- is either high or low in total carbon “lakes”). Metallographic determina- ance to dynamic impacts and content then it is possible to see tion of these features is outlined in internal structure. This is neither a third phase in the structure. For part 5 of ISO 4499. standardised nor quantified, but high C this is graphite; for low C it is clearly important for many

is eta phase (η) – typically an M6C or Palmqvist toughness test industrial applications of hard

M12C carbide where M is (CoxWy). The There are several possible methods materials. Also, principally for presence of these phases leads to for the measurement of the fracture hardmetals, it can be more realis- much lower strength and toughness toughness of hardmetals. The results tically assessed through either so it is important to identify them. can be expressed either as a stress fatigue tests or high-rate strength Part 4 of ISO 4499 is concerned with intensity factor, in MN.m-3/2, or as a tests, rather than a conventional Fig. 3 Palmqvist cracks at different applied loads Fig. 4 Effects of different abrasive types on abrasion test results the detection and measurement fracture surface energy, in J.m-2. The fracture toughness test.

The surface finish of the testpiece images. New methods are evolving more aggressive conditions. Suffi- Hardmetals (Part 1 Rationale and may affect the results of the test. that allow the orientation of phase cient research has been published for Results). Thus, the presence of a surface that constituents to be revealed through this approach to also be considered [3] B Roebuck. VAMAS Technical is altered by the preparation process colour coding (Fig. 5) [9,10]. These for standardisation, either through Report No 31, September 1997. may lead to increased initial wear. new methods have great potential, measuring electrochemical aspects Bend Strength Measurements for Conversely, the presence of residual both for improving the accuracy of (corrosion potentials) or simple mass Hardmetals, Part 2 - Analysis of stresses in the surface layer may microstructural metrology, but also loss techniques. Results. possibly affect initial wear processes. for providing new information relating Finally mechanical testing is well [4] B Roebuck. Effect of Testpiece In both cases when these surface to quality and performance that could served by many basic test methods, Geometry on the Flexure Strength regions are worn away, the wear rate not be studied with conventional such as for strength and hard- of Representative Hardmetals and should be expected to approach the methods. It is anticipated that these ness but there is much to be done Cermets. 14th Int Plansee Seminar, normal value for the material. new methods may lead to new stand- to review methods for assessing May 1997, Reutte, Austria, V2, 352 The test abrasive is important, ards in the near future. Also, physical aspects of force application, such 365. clearly, and should be obtained methods, such as X-ray diffraction, as the measurement of residual [5] B Roebuck, E G Bennett, L.A. Lay from a consistent source with good are commonly used as research tools stresses and also high rate aspects and R. Morrell. NPL(GPG)009, June quality control procedures to ensure to identify phase composition, but it such as impact and fatigue, as well 1998. The Measurement of Palmqvist that variability in its properties are is often difficult to reconcile results as elevated temperature properties, Toughness for Hard and Brittle minimised. It is also well known from different sources because for example, hot hardness, creep and Materials. that the results of abrasion testing the methods lack standardisation thermomechanical fatigue. However, [6] B Roebuck and E G Bennett. depend critically on the shape, size and information on such issues as all these subjects are probably more Hardmetal Toughness Tests, VAMAS and size distribution of the abrasive. system set-up, depth resolution, best challenging and longer term than the Report No.48, NPL, March 2005. For this reason, if it is important to practice for surface preparation and physical methods described above. [7] B Roebuck and E G Bennett. compare the results of one test with overall X-ray characteristics. At a Assessment of Toughness Tests for another, the same abrasive should be more fundamental level the extent Acknowledgements Hardmetals. PM 2004, World Confer- used in the tests concerned. It should of hard particle contact, usually ence, Vienna, Austria, Oct 2004. Fig. 5 Colour coded WC grains be noted that the results of abra- described as contiguity, is very The authors would like to recognise [8] M G Gee, A J Gant and B Roebuck. sion tests are dependent on many commonly alluded to as an important the substantial contribution by the Wear Mechanisms in Abrasion hardmetals using rotating-wheel can be carried out in the presence of different parameters such as the parameter controlling properties yet DIN secretariat in providing admin- and Erosion of WC/Co and Related systems. The test is appropriate for fluids, and whether the abrasive is abrasive material that is used, the again no standard exists for its meas- istrative guidance and support to Hardmetals, Wear of Materials, use in situations where test laborato- only used once and passes through abrasive shape, the size of the abra- urement or of the likely uncertainty in the ISO TC119/SC4 committee in Montreal, Canada, April, 2007, and ries have a need to simulate abrasive the test system, or is used many sive, the abrasive loading, the load, a given procedure. recent years. Particular thanks go Wear, 263, 2007, 137-148. damage. The procedure includes times. ISO 28080 specifies a common the speed, the environment and the Regarding physical aspects such to subcommittee colleagues Joe [9] K P Mingard, B Roebuck, E G information which enables the test to framework that brings together the counterbody material. This means as electrical and magnetic proper- Tauber, Mike Carpenter and Henk Bennett, M G Gee, H Nordenstrom, G be used in a variety of different condi- key features of these tests and gives that, to get repeatable and reproduc- ties a standard exists for magnetic van den Berg for their contribution Sweetman and P Chan. Comparison tions; with counterface wheels of results that show comparability, and ible results, it is extremely important coercivity that is essential for char- and experienced inputs to the stand- of EBSD and Conventional Methods different stiffness (for example steel also gives information on their repro- to ensure that the test conditions acterising the physical size of phase ards process. We would also like to of Grain Size Measurement of and rubber); wet and dry; different ducibility and repeatability. are reproduced. It is particularly constituents. However, although acknowledge input and guidance Hardmetals, Int. J. Refractory Metals abrasive sizes; and with different The mass loss, M, in kilograms important to use abrasive that is various techniques are often used from members of the relevant UK and and Hard Materials, 2009, 27(2), chemical environments. (kg), is calculated by subtracting the very similar to achieve comparable for measuring intrinsic magnetic German Hardmetal groups. 213-223. There are a number of abrasion value of mass measured at the end results. Because the results of these moments to help characterise the [10] K P Mingard, B Roebuck, J test methods that have been devel- of the test from the initial mass. This tests are so dependent on the abra- chemistry of the binder phase, these Authors Marshall and G Sweetman. Some oped that use this type of geometry, is converted to a volume loss V, in sive that is used, this often means methods have yet to be standardised. Aspects of the Structure of Cobalt 3 Bryan Roebuck & Eric Bennett including the ASTM G65 dry sand/ cubic metres (m ), using the equa- that the abrasive should be obtained Increasingly compositions are being and Nickel Binder Phases in National Physical Laboratory rubber wheel test, the ASTM G105 tion below, by using the measured from the same source. developed that are non-magnetic and Hardmetals. Acta Materialia, 59, Hampton Road wet sand/rubber wheel test and the testpiece density ρ, in kilograms per here electrical properties have poten- 2011, 2277-2290. 3 Teddington ASTM B611 steel wheel test. Other cubic metre (kg/m ). tial to be used for characterisation Potential future Middlesex, TW11 0LW variants of these tests have also been of structure and which are simple developments United Kingdom developed for specific applications M enough to be readily standardised. V = Tel: +44 20 8977 3222 in other institutes. These tests all ρ Considerable effort has been More and more materials are use a rotating wheel pressed against expended by the ISO TC199/SC4 being made that have “designed” a testpiece, with abrasive mate- There have not been any recent subcommittee in updating the heterogeneity in structure and References rials introduced between the wheel interlaboratory exercises on the ISO 4499 standard on microstruc- standard methods to characterise [1] B James, Powder Metallurgy and the testpiece. Because of this measurement uncertainty of rotating- ture and as examination techniques and report these heterogeneities are Standards, Powder Metallurgy fundamental commonality, much of wheel abrasion tests for hardmetals. advance in capability there is much likely to be under consideration as Review, Vol 2 No 4, Inovar Communi- the methodology is the same for the There is, nevertheless, some that could be done to enhance further tools for quality control and enhanced cations Ltd, 2013. different tests. However, they differ in information available on the repro- the scope of ISO 4499. For example, trading opportunities. Equally, corro- [2] B Roebuck, VAMAS Tech- the details of how the abrasive is fed ducibility and repeatability of these conventional microscopy has largely sion resistance is of great importance nical Report No 22, June 1996. to the interface between the wheel measurements [8]. been based on optical and scan- as applications expand into more and Bend Strength Measurements for and the testpiece, whether the test ning electron secondary electron

PM2014 World Congress: Global Powder Metallurgy industry sustains growth momentum

Following a period of severe recession in 2008 and 2009, the global PM industry is once again on a path of sustained growth, as was illustrated in the presentations given by Richard Pfingstler, MPIF President, Philippe Gundermann, EPMA President, and Mamoru Moritani, JPMA President, in the ‘Global Trends’ plenary session at the PM2014 World Congress held in Orlando, May 18-22. Powder Metallurgy Review reports on the three presentations.

The Powder Metallurgy powder shipments increased 4.62% cals and food additives. However industry in North America to 401,738 st (364,450 mt), surpassing placing 2013 shipments into perspec- the 400,000 short ton mark for the tive there is still some way to go to The North American PM industry first time since 2007 (Fig. 1). regain the record iron powder ship- is continuing to recover from the The PM parts portion of this ment level of 473,804 st (430,000 mt) deepest collapse of the US economy amount increased by just over 5% achieved in 2004. since the Great Depression, reported to 361,150 st (327,629 mt), with the In 2013 shipments of copper and Richard Pfingstler, MPIF President. remainder going into welding, chemi- copper-base powders increased by The more recent “Great Recession” saw iron powder shipments, the statistic most indicative of the PM North American Iron Powder Shipments industry’s health, collapse by 19% in Short tons 2008 followed by an even more disas- Total 500,000 401,738 trous reduction of 25% to 212,327 st 400,000 (192,619 mt) in 2009, the lowest level PM parts in 18 years. 300,000 total Pfingster described the recovery 361,159 200,000 since 2010 as a classic comeback story, in which an industry rallies an 100,000 inner strength rooted in its long tradi- 0 tion of entrepreneurial grit. “Most 2006 2007 2008 2009 2010 2011 2012 2013 of the sectors of PM and particulate PM Parts Welding Other uses materials have all bounced back and are continuing to grow at a steady Fig. 1 North American iron powder shipments (in short tons) to 2013 (Source pace” reported Pfingstler. 2013 iron MPIF)

businesses, which still struggle with Additive Manufacturing that the MPIF Technical Board 2014 Four cylinder engine cars use less North American Copper and Copper-base Powder Shipments scarce access to capital and with the Additive Manufacturing (AM) was technology assessment programme weight of PM parts and about two- economic and administrative burdens featured for the first time in the PM is studying how to reduce dimen- thirds as many PF connecting rods Short tons of complying with increasing federal World Congress series in Orlando sional variability in ferrous PM parts and bearing caps. Nevertheless, 20,000 16,850 and state regulations. The inability of with an inaugural conference and processes. The programme will opportunities abound for PM parts in smaller PM shops to attract younger dedicated to this rapidly evolving identify process factors such as raw 15,000 all-wheel-drive systems, start-stop engineering talent to work in manu- technology. Pfingstler stated that AM materials, compaction, sintering and systems, new diesel engines, and 10,000 facturing plants is another challenge, is evolving into a serious business secondary operations that are likely more-complex and lighter-weight PM stated Pfingstler. model that goes beyond designing to cause the greatest variation in part 5,000 gears. prototypes. He said that there are dimensions. The ultimate goal is to It is estimated that the US PM gear 0 Non press & sinter markets an estimated 100 to 200 AM metal improve dimensional tolerances by at market could reach as high as 250,000 2006 2007 2008 2009 2010 2011 2012 2013 Looking beyond the traditional printers installed in the US providing least 50%. st (225,000 mt). New cost effective PM PM Parts press-and-sinter PM sector, Pfingl- custom manufacturing and prototype A number of powder producers high-speed steels are being consid- ster noted that the refractory metals services, including captive installa- have introduced new materials ered for automotive valve guides and markets softened somewhat last tions doing development work as well offering powders with a high density Fig.2 North American copper and copper-base powder shipments for PM to seats that improve on the quality of year and there was more untapped as R&D programs at government and lubricant-binder system allowing 2013 (Source MPIF) existing materials. The PM content in capacity in 2013 than 2012. The Hot university laboratories. green densities above 7.5 g/cm3 a typical US light vehicle rose slightly Isostatic Pressing (HIP) business is an estimated 4% to 16,850 st (15,286 highest in 13 years. This has led to in 2013 to an estimated 44.5 pounds enjoying healthly growth particularly mt) in 2013 (Fig. 2), whilst stainless PM parts makers investing to expand (20.2 kg), up from 43.7 pounds in 2012. for densifying MIM parts, a significant “Our challenge, no matter how large or steel powders gained by an estimated capacity and increase their capability The forecast for 2014 is for a very trend during the last three years. 3.5% to 7,600 st (6895 mt). Nickel to meet more-exacting customer modest increase to 44.6 pounds. small our companies, is to maintain that About 50 to 60% of MIM firearms powder shipments were estimated specifications for more-complex Pfingstler said that most PM and medical parts are HIPed and the energy and entrepreneurial grit. We must to have increased by 5% to 5,775 st designs and higher-performance parts markets are projected to see HIPing of MIM aerospace parts is (5240 mt) in 2013. parts, stated Pfingstler. modest growth in 2014, which will always look to improve what we do, and also a growing market. The resurgence in demand for However, the MPIF president result in a modest rise in metal A future growth area for HIP is never stop investing in new talent” iron and steel powders reflects rising cautioned that the trend toward powder shipments, again in the Additive Manufacturing (AM). It is North American light-vehicle produc- smaller, fuel efficient engines and region of 5%. Hampering an even anticipated that specifications for AM End markets for AM extend over a with green strength double that tion that topped 16 million units in away from those with six and eight higher growth rate are the chal- parts will require HIPing to ensure wide range from dental products such of standard lubricants. PM press 2013 according to WardsAuto, the cylinders is a serious threat to PM. lenges faced by smaller family-owned full density for certain applications, as tooth bridges and copings, medical builders, who saw compacting press especially in the aerospace sector. implants, aerospace components, deliveries exceed 25 units in 2013, automotive parts, injection moulding are building presses with higher Metal Injection Moulding moulds, jewellery, watch cases, and technology capabilities to meet the Sign-up for our Pfingstler reported that the North satellite parts being just some exam- demand for more complex designed American Metal Injection Moulding ples. Pfingstler stated that one major PM parts with closer tolerances. (MIM) market continues to enjoy US aerospace company is building a The Center for Powder Metallurgy new metal Additive robust growth. MIM grade powder massive plant to produce engine fuel Technology (CPMT) has been active shipments increased substantially nozzles from cobalt-chrome powder. in fatigue testing studies, and in Manufacturing to an estimated 1125 to 1440 mt in Excluding titanium, the bulk of the 2013 the Center released a technical 2013. The current US MIM parts busi- 100,000 lbs/year (45 mt/year) of gas report on Strain-Based Fatigue for e-newsletter ness represents about 70 companies atomised spherical powders for the Four PM Materials. A final report of which an estimated 25%, or 18 AM market is currently supplied by six on the single-tooth bending fatigue companies, are captive operations. companies. programme and the third strain- The total value of MIM industry The decision to co-locate the based fatigue report covering three sales in 2013 is estimated to be in the AMPM conference with the PM2014 PM materials will be released later in www.metal-am.com region of $300 to $350 million and World Congress “was envisioned as 2014. In addition, MPIF has recently this is expected to grow by 10 to 15% a way to open communication among formed an aluminium standards in 2014. Beyond MIM’s traditional all our industry segments,” the MPIF subcommittee to provide new mate- parts markets, which include fire- president said. rials data on aluminium PM, particu- arms, medical/dental, general indus- larly aimed at automotive engineers trial, automotive, and electronics, the Investing in new technology seeking to use more lightweight automotive market in North America In order to maintain the upward materials to meet CAFE standards. METAL looks especially promising for MIM trajectory of its growth pattern, In closing, the MPIF president parts that go into fuel injection and Pfingstler stated that the PM noted that the industry is alive and ADDITIVE turbocharger applications. Aerospace industry must continue to invest in well, introducing new products, engineers are considering specifying new technology in order to improve materials, and processes. “As a MIM parts in the next generation of materials, product performance, and modern, 21st century technology MANUFACTURING aircraft engines. dimensional tolerances. He reported with a rich history, PM continues to

competition from low cost countries. revenue for AM products grew by 40% European PM Production 2013 Non-ferrous PM powder (Cu-base) in 2012 to €18 million and that double PM Production Asia shipments were shown to make digit growth is expected to continue in Tons MIM up 7%, or 14,490 mt, of total PM the years ahead. 160,000 1% China production, an increase of 13.4% on As with MIM, the European AM 140,000 Hard materials the powder shipments for 2012. Hard sector has a very strong supply chain 7% 120,000 Structural materials also made up 7% of the both in the equipment for producing Japan HIP ferrous total in 2013. AM products and in the metal 100,000 3% 82% powders required. Many applications 80,000 Metal Injection Moulding are foreseen in the aerospace and Structural Korea non-ferrous The Metal Injection Moulding (MIM) other sectors. The EPMA formed 60,000 7% market in Europe is estimated by the new European Additive Manu- India 40,000 the EPMA to consume around 2,000 facturing Group in 2013 with over 30 mt of metal powders annually, with members. 20,000 Taiwan Fig. 3 Breakdown of European PM production in 2013 by weight (Source EPMA) a strong growth in sales in 2013 to Concluding, Gundermann stated 0 just over €250 million (Fig. 4). Around that the European PM industry is 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 50% of MIM parts are made from blessed with a very strong R&D MIM Part Sales Europe stainless steel grades, 25% low alloy base with at least 20 significant Fig. 5 PM production in the five major countries in Asia to 2013 (Source APMA) 300 steel, 5% soft magnetic mate- centres for academic research as rials, 1% titanium and 19% others. well as numerous independent RTD 250 Gundermann reported that there are suppliers. HIP and AM are the hot MIM Sales Asia some 40 to 50 MIM part producers topics, he said. He invited delegates 200 in Europe supported by a strong to come to the next PM world Taiwan, 35 Million USD

s supply chain for feedstock, injection congress and exhibition which will be o

r India, 70

u 150 moulding equipment and debinding/ held in Hamburg, Germany, October E

n sintering furnaces. 9-13, 2016. o i l l i 100 European MIM companies seem to Korea, 25 China, 230 M be less prone to developing their own Powder Metallurgy in Asia 50 feedstock and debinding processes compared with their North American Mamuro Moritani, President of the 0 counterparts. Automotive applica- Japan Powder Metallurgy Associa- 1991 1997 2003 2010 2011 20112 2013 tions for MIM also make up a higher tion presented a review of the state Japan, 110 market share than other regions. of the PM and MIM industries in Asia Fig. 4 Metal Injection Moulded part sales in Europe to 2013 with specific reference to ferrous and Fig. 6 MIM sales in Asia to 2012 (Source JPMA MIM Market Research/ Kato Hot Isostatic Pressing non-ferrous PM grade powder ship- Professional Engineer Office) reinvent itself. We are innovative and the same period in 2013. This is The Hot Isostatic Pressing (HIP) ments in Japan. Moritani stated that entrepreneurial right down to our essentially on the back of a strong sector is also thriving in Europe, PM production in Asia is now domi- DNA,” stated Pfingstler. “Our chal- recovery in the European automotive stated Gundermann. The European nated by China which has been the Powder Metallurgy Association shipments is attributed to a general lenge, no matter how large or small market which has seen the biggest HIP market has a 45% share of the largest Powder Metallurgy producer (APMA) had successfully organised weight reduction of PM self-lubri- our companies, is to maintain that revival in demand for cars since the global market with around 25% of since it overtook Japan in 2009. PM PM conferences in Jeju, Korea (2011) cating bearings due to the downsizing energy and entrepreneurial grit. We major slump in 2009. HIPing in Europe involving powder- production surged again in China in and Xiamen, China (2013) with the of automobiles and the trend towards must always look to improve what Gundermann stated that ferrous based products. Some 14,000 mt of 2013 rising to close to 160,000 mt venue for 2015 being announced as miniaturisation in electronic equip- we do, and never stop investing in PM production in Europe made up high alloy steels (stainless, HSS, and compared with around 140,000 mt the Kyoto from October 18-20. The APMA ment. new talent. In the end, we are still a 82%, or 169,740 mt, of the total of tool steels) were produced in 2013 previous year. will organise the next PM World special industry with a bright future.” 207,000 mt for all PM products (Fig. 3). mainly using large capacity HIP units, China is forecast to maintain the Congress and Exhibition in Beijing in Metal Injection Moulding However, whilst ferrous PM powder some of which are now capable of highest PM production volumes 2018. Moritani reported that the JPMA is The status of Powder shipments have seen positive growth processing 30 tonne loads with faster in the region for the foreseeable Referring to trends in the Japa- actively promoting powder metal- Metallurgy in Europe since 2010, they are still some way cycle times thanks to uniform rapid future, stated Moritani. In Japan, the nese PM industry, Moritani stated lurgy and MIM in Japan, especially to off the record of almost 200,000 mt of cooling. The cost of HIPing relative region’s second largest PM producer, that PM grade iron powder ship- young company employees. 13 MIM Philippe Gundermann, President of ferrous PM powders shipped in 2007. to energy and materials costs has production in 2013 was level with ments reached 108,883 mt in 2013, a member companies of the JPMA are the European Powder Metallurgy Gundermann further stated that decreased by 65% over the last two 2012, whilst Korea showed a slight small decline on 2012 and was still also supporting the development Association (EPMA) reported that there is now a steady expansion decades, stated Gundermann. increase, as did Taiwan (Fig. 5). Thai- some way off the 127,000 mt record of standards for the rotating bend the European PM industry enjoyed in volume terms in a fairly stable land saw production fall, in Malaysia achieved in 2007. Copper powder fatigue properties of MIM materials moderate but sustained growth in PM part market in Europe, with Additive Manufacturing production was even with 2012, and shipment figures for PM also showed including stainless steels, Ti and 2013 and early indications are that increased product sophistication Europe, like North America, has Indonesia entered the frame for a slight decrease with 4,768 mt Ti6Al4V alloys. The work is being 2014 will be even better, with first allowing higher prices and improved seen a surge in interest in the use of the first time with PM production at shipped in 2013 compared with 4,848 carried out at Kyusyu University, quarter 2014 iron powder shipment profit margins. However, the PM Additive Manufacturing (AM) in recent around 2500 mt. mt shipped in 2012. The continuing Japan. figures showing a 20% increase over industry faces some overcapacity and years and Gundermann reported that Moritani stated that the Asian recent decline in copper powder

MPIF Powder Metallurgy Design Excellence Awards 2014: Innovations drive new applications

Winning parts in the Metal Powder Industry Federation’s (MPIF) 2014 Powder Metallurgy Design Excellence Awards competition were announced at the PM2014 World Congress, Orlando, USA, May 18-22. The annual awards provide a showcase for the Powder Metallurgy (PM) community, demonstrating the latest design and manufacturing developments that enable PM to move into new markets.

The awards presented by the Metal Grand Prize Awards assembly made for its customer Powder Industries Federation prove Ford Motor Company (Fig. 1). once again that Powder Metallurgy Automotive Transmission The 32 part carrier assembly is is a key technology for end-users Keystone Powdered Metal used in the HF35 hybrid transmis- who operate in demanding and highly Company, St. Marys, Pennsylvania, sion that goes into Lincoln MKZ, competitive environments. USA, was awarded a Grand Prize Ford C-Max, and Ford Fusion hybrid Powder Metallurgy gives designers in the Automotive Transmission vehicles. The spider and carrier plate and engineers the freedom to Category for a planetary carrier are compacted and then sinterbrazed conceive shapes that are impractical to achieve by traditional processes. The PM industry continues to push the boundaries of complexity, tolerances, and mechanical properties past their already impressive scope, expanding into new applications and extending opportunities within existing applications. As well as awards for press and sinter components, the MPIF presented eight awards to parts manufactured via Metal Injec- tion Moulding (MIM), reflecting the continued growth and importance of this sector. A full report on the MIM awards is available in our sister publication, PIM International Vol 8, Fig. 1 The award winning carrier assembly incorporates seven PM parts No 3. (Courtesy MPIF)

free removal from the lower punches. Despite their tremendous shape complexity, these parts are formed to net shape. Specially developed sintering fixtures ensure that flat- ness and level-to-level relationships are maintained. As a new technology in this product category, this intuitive differential is expected to set the standard for the tight-turning requirements for machines of this type.

Awards of Distinction

Automotive -Transmission Cloyes Gear & Products, Inc., Paris, Arkansas, USA, won the Award of Distinction in the Automotive -Transmission Category for a ball Fig. 2 The PM parts are used in a disengagement mechanism (Courtesy MPIF) ramp actuator comprising a sector Fig. 5 This PM part operates in the transmission of large Fig. 6 This bathtub drain tool is an assembly of five PM gear and fixed ring, made for Magna motorcycles (Courtesy MPIF) parts (Courtesy MPIF) together before being joined to the Lawn & Garden/Off-Highway Powertrain (Fig. 3). shaft. The helical pinion gears are Capstan, Wrentham, Massachusetts, The actuator applies torque to the Lawn & Garden/Off-Highway Hand Tools/ Recreation Hand Tools/ Recreation sinter forged to full density using USA, received the Grand Prize in front wheels in the BMW high-perfor- Lovejoy Powder Metal Group, A sinter-hardened steel retainer A further Award of Distinction in the tools that must also rotate and the Lawn & Garden/Off-Highway mance X-Drive transfer case that Downers Grove, Illinois, USA, weight made by Hitachi Chemical Co., Hand Tools/ Recreation Category exactly match the gears’ 24.5 degree Category for copper-steel parts made goes into various BMW platforms. won the Award of Distinction in Ltd., Chiba, Japan, won an Award of was given to MPP Ridgway, Ridgway, angle; it is the first time such a gear for General Transmission. The parts Warm compacted from a hybrid the Lawn & Garden/Off-Highway Distinction in the Hand Tools/Recrea- Pennsylvania, USA, for this bathtub has been used in an automotive make up a disengagement mecha- low-alloy steel, the parts replaced Category for a parking/emergency tion Category. The part operates in drain tool made for ezXtractor. The transmission application. nism of an intuitive differential snow- forged components that had been brake piston for hydraulic trans- the transmission of large motorcy- tool is an assembly of five PM parts; It is estimated the customer blower system that allows the user to used in an earlier transfer case missions used in zero-turn-radius cles, controlling the on/off position of two drain wings, drain top, drain achieved cost savings on the order of pivot the unit in place by disengaging design, and provided 35% cost lawn maintenance equipment the clutch (Fig. 5). bottom and drain shaft, all made from 25% by going this route. In over two one of the wheels (Fig. 2). savings over the forgings. The manu- (Fig. 4). The challenge of attaining dimen- FN-0405 modified nickel steel (Fig. 6). years of production of this carrier, These two parts combine eleven facturer delivers in excess of 700,000 Made from FC-0208 iron-copper sional accuracy in a component The innovative design maxim- with about a quarter of a million pressing levels, requiring precisely actuators annually through this steel, the piston is compacted with with such a thin, large-diameter ises the benefits of PM technology assemblies shipped, there have been timed tool motions at ejection, along global program. three features on top and six on the shape was overcome with process while simplifying complexity for easy no field returns. with sophisticated robotics, for crack- bottom, using two upper and three optimisation and the choice of steam assembly with two circlips and two lower punches plus a die shelf. treatment. This redesign of a previous dowel pins. The two integral cams on The part is an original design PM part achieved a 17% weight the shaft create the action that forces for PM, as its shape makes it reduction. The manufacturer antici- the grippers into the pipe ID. The impractical for traditional metal- pates this accomplishment could parts are produced to net shape with cutting methods. It is pressed and open the door to additional oppor- two machined grooves for the circlips sintered to net shape, requiring no tunities in the small to medium-size being the only secondary operations secondary machining operations. motorcycle market. needed.

Metal Injection Moulding award winning parts

Eight awards were presented by the MPIF for parts manufactured via Metal Injection Moulding (MIM). A full report on these is available in PIM International Vol 8, No 3. Download your free copy Fig. 3 The actuator is used in BMW’s high-performance Fig. 4 The award winning parking/emergency brake piston at www.pim-international.com X-Drive transfer case (Courtesy MPIF) for hydraulic transmissions (Courtesy MPIF)

86 Powder Metallurgy Review Autumn / Fall 2014 © 2014 Inovar Communications Ltd © 2014 Inovar Communications Ltd Autumn / Fall 2014 Powder Metallurgy Review 87 A4_Anzeige_Ho?gana?s_040713 24.07.2013 8:02 Uhr Seite 1

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Euro PM2014 ACE Iron & Metal Co. 31 E-Presses from The Number One in PM-Technology September 21-24, AIMS 59 Salzburg, Austria ALD Vacuum Technologies 21 www.epma.com American Isostatic Presses, Inc. 61 Ametek 17 International Conference on Deformation and AM/PM Conference 78 Fracture in PM Materials Avure 54 October 26-29 Ceramitec 2015 53 High Tatras, Slovakia China PM Business website 28 www.imr.saske.sk Codina 32 Metal Additive Manufacturing Conference 2014 Cremer Thermoprozessanlagen GmbH 36 November 20-21 Dorst Technologies Inside back cover fast precise lowenergy Vienna, Austria DSH Technologies 7 x x www.additivemanufacturing2014.org EPSI 63 Erasteel 20 EuroMold Euro PM2015 Congress and Exhibition 68 November 25-28 Fluidtherm 10 Frankfurt/Main, Germany GGP Metalpowder AG 24 www.euromold.com Graphit Kropfmühl 26 Hanrui Cobalt 27 2015 Harper International 35 HC Starck 57 PM15 International Conference & Exhibition Hoeganaes Corporation Inside front cover January 19-21 Höganäs AB Outside back cover Mumbai, India Hua Cheng Steel Die Co Ltd 11 www.pmai.in/pm15/ Imerys Graphite & Carbon 6 Institut Dr. Foerster GmbH & Co. KG 22 MIM 2015 Ipsen Inc. 2 February 23-25 Jayesh Industries Ltd. 29 Tampa, Florida, USA Lonza Inc. 23 www.mpif.org Loomis Products Kahlefeld GmbH 5 Makin Metal Powders 9 PM China 2015 Expo Metal Additive Manufacturing 80 April 27-29 MIM 2015 67 Shanghai, China Osterwalder AG 12 www.cn-pmexpo.com/en/ PIM International 42 PowderMet2015 / AMPM Powdermet 2015 44 May 17–20 PM15 India 84 San Diego, CA, USA PM China Exhibition 39 www.mpif.org PVA TePla 30 Retsch Technology 15 Rio Tinto QMP 4 Royal Metal Powders 33 ADVERTISING Ruhstrat 14 POWDER METALLURGY Sandvik 13 To discuss advertising in Powder NO.1 VOL.1 2012 AUTUMN/FALL REVIEW SCM Metal Products, Inc. 19 Metallurgy Review contact: Steuler KCH GmbH 18 Jon Craxford, Sunrock Ceramics 34 Advertising Sales Director Swastik Tungsten Private Limited 41

TRENDS IN HIP TECHNOLOGY Tel: +44 207 1939 749 DEVELOPMENTS IN PM ALUMINIUM MPIF AWARD WINNING PARTS System 3R 37 [email protected] Published by Inovar Communications Ltd ipmd.net United States Metal Powders, Inc. 25 W E BRING CERA MICS A ND META L P OW DER IN TO SH A P E

Helical gear compaction capability, a low pressure carburising & gas quench technology for cost effective combination of sintering and heat treatment, gear fatigue testing capability as well as a new generation 70 ton multi-platen electric press. These are only some of the latest additions to our PoP Centre. In a team approach involving the entire supply chain--from powder manufacturer to part producers and gearbox manufacturers-- we now utilise our combined capabilities to pave the way for new PM transmission solutions.

We have already proven that bending and impact stresses as well as noise characteristics and inertia/weight can be improved with smart PM gear concepts. With the joint re-engineering of a 6-speed manual transmission we intend to once again demonstrate that PM solutions belongs to the future of transmission technology.

Visit us in stand no. 69 at Euro PM2014 Congress & Exhibition