Höganäs Digital Metal® Produces Highly Complex and Intricate Designs with 3D Printing

POWDER METALLURGY

VOL. 2 NO. 3 VOL. 2013 AUTUMN/FALL REVIEW

AUTOMOTIVE PM IN NORTH AMERICA HARDMETAL INNOVATIONS AT PLANSEE 2013 ADVANCES IN PM AT POWDERMET 2013

Published by Inovar Communications Ltd ipmd.net THE FUTURE OF PM SOLUTIONS HAS ARRIVED! AUTOMOTIVE

The potential of powder metallurgy is only HEAVY INDUSTRY limited by one’s imagination… To that end, from developing new materials that lead to property advancements or PM process e ciency, to working with AEROSPACE our customers to achieve the most cost e cient solutions using PM technology, we are committed to providing powder metallurgy solutions…serving our customers in every part of the world! OFF ROAD And, along the way, be assured we will continue to invest in manufacturing capacity to support industry growth globally while providing design, process, and material system LAWN & GARDEN education wherever it is needed.

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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 Tel: +44 (0)1743 454992 Email: [email protected]

SOLUTIONS FOR TOMORROW Assistant Editor Sarah Scarratt Tel: +44 (0)1743 454990 Email: [email protected] E-Presses from The Number One in PM-Technology Managing Director Challenges and opportunities Nick Williams Tel: +44 (0)1743 454991 Email: [email protected] as the auto industry adapts to a

Accuracy of contents new global environment Whilst every effort has been made to ensure the accuracy of the information in this publication, the publisher accepts no responsibility for In this latest issue of Powder Metallurgy Review we feature a errors or omissions or for any consequences specially commissioned report on the evolving relationship between arising there from. Inovar Communications Ltd North America’s PM parts producers and the region’s automotive cannot be held responsible for views or claims industry (page 33), which has dominated the development of the expressed by contributors or advertisers, which PM industry for many decades. Eric Boreczky charts the rapid are not necessarily those of the publisher. growth of the PM industry in the 1990s following the introduction of fast x precise x lowenergy Reproduction, storage and usage a number of major new applications, as well as the impact of the Single photocopies of articles may be made recession of 2008. Boreczky also considers the challenges that lie for personal use in accordance with national ahead as the globalisation vehicle design leads to smaller more fuel copyright laws. Permission of the publisher and payment of fees may be required for all other efficient engines. photocopying. All rights reserved. Except as outlined above, no part of this publication may At the PowderMet 2013 conference held in Chicago in June there be reproduced, stored in a retrieval system, was much optimism for PM’s future, with new developments or transmitted in any form or by any means, in materials, processing technologies and applications being electronic, photocopying or otherwise, without prior permission of the publisher and copyright presented for both the automotive and non-automotive sectors. owner. Powder Metallurgy Review was present at this important annual event and Dr David Whittaker reports on a Special Interest Program Submitting news and articles that looked at Technologies for PM Growth (page 57). We welcome contributions from both industry and academia and are always interested to hear about company news, innovative There was also much to discuss in the hard materials presentations applications for PM, technology developments, at the triennial Plansee Seminar which took place in June in Reutte, research and more. Austria. Dr Leo Prakash reports for Powder Metallurgy Review Please send all submissions to Paul Whittaker; on presentations covering global R&D trends in hardmetals and Email: [email protected] the phenomena of cobalt capping (page 41). More in this series of Tel: +44 (0)1743 454992 exclusive reports can be found on our website www.ipmd.net. Subscriptions Powder Metallurgy Review is published on The growth in the global demand for electric motors also has huge a quarterly basis. It is available as a free potential for the use of iron-base Soft Magnetic Composites. We electronic publication or as a paid print report on the development by GKN Sinter Metals, in conjunction subscription. The annual subscription charge is with RWTH Aachen, of a new transversal flux motor which uses £85.00 including shipping. Rates in € and US$ are available on application. SMC iron powders in the stators of a new electric motor (page 75).

Advertising opportunities Paul Whittaker Contact Jon Craxford, Advertising Director, Editor, Powder Metallurgy Review to discuss how we can help promote your products and brand, both online and in print.

See the new multi-platen Tel: +44 (0) 207 1939 749 Fax: +44 (0) 1743 469 909 Electric Press EP 70M Email: [email protected]

at Höganäs Design and production Inovar Communications Ltd. Power of Powder Day ISSN 2050-9693 (Print edition) ISSN 2050-9707 (Online edition) September 18, 2013 Cover image © 2013 Inovar Communications Ltd. 2013 MPIF award winning compressor clutch used in a braking system, manufactured by AMES SA, Spain (Courtesy MPIF) WE BRING CERAMICS AND METAL POWDER INTO SHAPE ipmd.net

27 31 33 44 63 in this issue

33 North America’s PM industry: The challenges 57 PowderMet 2013: Technical developments of an evolving automotive market offer growth for the PM industry In the 1990s North America’s PM industry enjoyed rapid A Special Interest Program at PowderMet 2013 growth thanks to a dramatic increase in the quantity proved to be an excellent opportunity to showcase the and weight of PM components used in US automobiles. advances in PM material and process developments. The recession of 2008, a drive towards smaller and Dr David Whittaker reports on a number of key more fuel efficient vehicles and the globalisation presentations. of engine and gearbox development has however dramatically changed the landscape for the region’s PM 69 MPIF 2013 award winning PM parts showcase producers. Eric Boreczky reviews the recent history of PM in North America and considers the challenges that an innovative industry lie ahead in adapting to a changing automotive market. Winning parts in the MPIF 2013 PM Design Excellence Awards competition were announced at PowderMet 41 Plansee Seminar 2013: The global refractory 2013. The award winners provide a showcase for Powder Metallurgy, demonstrating the latest design metals and hard materials industry meets in and manufacturing developments in the industry. Austria The 18th Plansee Seminar organised by the Plansee 75 Soft Magnetic Composites in the Group was held in Reutte, Austria, from the June development of a new compact transversal 3-7 2013. Dr Leo Prakash reports on presentations flux electric motor highlighting global R&D trends and the phenomena of cobalt capping. GKN Sinter Metals and RWTH Aachen have collaborated to develop a new transversal flux motor (TFM) which 51 PowderMet 2013: State of the North American uses Soft Magnetic Composite (SMC) iron powders in the stators of the motor. We report on a presentation given Powder Metallurgy industry Worldwide Stefan Tiller, GKN Sinter Metals, on the development of Global manufacturer of nodular and spherical aluminum powders, The PowderMet 2013 International Conference on PM the new TFM e-motor. pre-alloyed aluminum powders, and aluminum premixes for PM and Particulate Materials was held in Chicago, USA, from June 24-27. Organised by the Metal Powder www.ampal-inc.com www.poudres-hermillon.com Industries Federation (MPIF), the event attracted over 800 participants and included three days of regular features In the Americas presentations and a trade exhibition. A keynote Supplier of carbonyl iron and atomized stainless steel powders for presentation by MPIF President Matthew Bulger gave 5 Industry news the PM and MIM industries delegates a detailed overview of the current state of the North American Powder Metallurgy industry. 80 Advertisers’ index United States Metal Powders, Incorporated 80 Events guide 408 U.S. Highway 202, Flemington, New Jersey 08822 USA Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 email: [email protected] © 2013 Inovar Communications Ltd Autumn/Fall 2013 Powder Metallurgy Review 3

Debind & Sinter industry news To submit news for inclusion in Powder Metallurgy Review contact Paul Whittaker [email protected]

China’s PM industry maintains Rio Tinto plans growth in 2nd quarter 2013 new metal powder ® TITAN DS delivers the best in…debinding and sintering. Statistics published by the China the first half year to 85,165 tonnes, an annealing plant in Machine Powder Metallurgy Associa- increase of 8.7% compared with the tion (CMPMA) show that structural PM same period in 2012. India part production maintained its growth In terms of sales value the CMPMA According to a report published on momentum in the 2nd quarter of 2013 reported an increase of 7.3% for the India’s dna website, Rio Tinto has an- with output increasing to 45,124 tonnes, first half year at Yuan 2,860 million nounced plans to set up a new metal Backed by 65 years of thermal processing expertise, Ipsen’s new sintering and which is a 12.6% increase compared ($467 million). The figures are based powder annealing plant at Bharuch, debinding furnace, TITAN® DS, upholds our reputation for quality. Ipsen delivers the with the previous (1st) quarter of 2013. on the responses from 47 PM enter- India. This takes total PM production for prises to the CMPMA best through better performance and better features for less cost, bringing the MIM A Rio Tinto official told the daily broadsheet “The project covers and Powder Metallurgy industry one step forward. an option to build a metal powder GKN continues to annealing plant. A modest investment Benefits and the time frame is still uncertain.” make good progress in 2013 “Global demand for metal powders • Reduced door-to-door cycle time Group results issued by GKN plc for year’s acquisition, GKN Aerospace is driven mainly by the automotive sector, where manufacturers are • Unbeatable price-to-volume ratio for specialized MIM furnaces the first six months trading in 2013 Engine Systems (formerly Volvo showed that sales increased by 12% to Aero), which is performing well. The increasing their intensity of use to • Precise process control for consistent part quality £3,647 million (up 2% on organic basis) first half met our expectations and, lower automobile weight and increase compared with the same period in with planned restructuring costs fuel efficiency. Metal powders are also • Short delivery time with rapid start-up 2012. Reported profit before tax of £134 now behind us, we expect a stronger used in the fabrication of home appli- • One global standard million (2012: £279 million) was lower, second half performance and to deliver ance and power tool components, and primarily due to foreign exchange rate good progress in 2013,” stated Nigel as food supplements,” the company • Modular design for ease of production flow optimization changes. Stein, Chief Executive of GKN. added. “GKN has continued to make good The GKN Powder Metallurgy Divi- The report stated that it is likely progress against our strategy to grow sion sales grew by 2% to £480 million that the proposed plant in Bharuch Technical Information would be supplied with raw atomised a market-leading global engineering in the six month period with a trading powder from Rio Tinto’s metal powder • Work zone size: 915 mm x 915 mm x 1,220 mm (36” x 36” x 48”) business. Although some of our end margin of 10%. The PM Division is markets remained challenging, we expected to show good year-on-year plant in Tracy, Canada. • Hearth gross load weight capacity: 2,700 kg (6,000 lbs) continued to outperform and are sales improvement, although reflecting www.riotinto.com reporting good underlying financial normal seasonality. • Maximum operating temperature: 1,400°C (2,550°F) results with further benefit from last www.gkn.com • Temperature uniformity: better than +/- 5°C (+/- 10°F) • Ultimate vacuum level: < 7 Pa (50 microns) • Nitrogen, hydrogen and argon partial pressure for operation up to 13 mbar (10 Torr) • Internal nitrogen or argon gas cooling up to 2 bar • 3 heat trim zones

Visit www.IpsenUSA.com/TITANDS to learn more about TITAN DS.

www.IpsenUSA.com/TITANDS 4 Powder Metallurgy Review Autumn / Fall 2013 © 2013 Inovar Communications Ltd © 2013 Inovar Communications Ltd Autumn / Fall 2013 Powder Metallurgy Review 5 QMP_pub_1212460_Mise en page 1 2012-12-12 13:48 Page1

the downturn is only marginal, Höganäs reports increase in sales the company states that austerity measures in Europe appear to be volumes in second quarter 2013 holding the region’s recovery in check in several market segments. Sales Höganäs AB has reported sales vol- other emerging markets in the spring. performance in Asia was pushed in umes in the second quarter 2013 were In Europe, we saw a marginal sales a positive direction by China, while up 2% compared to the corresponding increase, thanks to Eastern Europe,” strong comparative figures for 2012, period of the previous year. However, stated Alrik Danielson, Chief Execu- due to the recovery post-tsunami and the Swedish metal powder producer tive Officer. “Thus, Höganäs’ broad flooding, meant most other countries recorded a 9% drop in net sales year geographical diversity meant that reported sales downturns. on year, with net sales of MSEK 1,652 sales volumes for the first half-year Healthy growth was achieved in for the period, compared with MSEK were fairly good overall. However, to North America as continued positive 1,808 in Q2 2012. reduce the risk of holding excessive car production forecasts and market As an effect of falling metal prices, inventories in the autumn, we decided sentiment improved in many other metal price surcharges on all signifi- to run lower production volumes than segments. In South America high cant metals were lower than in the the previous year in the spring, as inventories at the customer level second quarter 2012 added Höganäs. reflected in our improved cash flow.” caused fairly weak sales early in the The Swedish krona remained volatile period, stated Höganäs. The growth in the quarter and overall the currency First half 2013 stimulus measures the Brazilian effect on sales values was 7% negative The company reported first half 2013 government has taken in the past two compared to the previous year. net sales of MSEK 3,229, down 11% years did generate a gradual positive “Global market progress presents a year on year. Sales volumes were also effect, and volume performance divided picture. We are satisfied to see down 0.3% in the period. progress in the second quarter was the progress of our volumes in North Höganäs stated that sales volumes gradually more positive. America and China, while demand in Europe were down on the corre- www.hoganas.com conditions were sluggish on some sponding period of 2012. Although

Plansee Group announces second New President From Ore To Powder, most successful year ever and CEO at To Meet Your Requirements! With the divisions Plansee High that, “bearing in mind that we have PMG Indiana Performance Materials, Global had to operate in a global market envi- Corporation Metal Powders Tungsten & Powders (GTP), Ceratizit ronment characterised by uncertainty (hardmetal tools and wear parts), and and that previously booming China PMG Holding GmbH, headquartered www.qmp-powders.com the investment in Molymet, Austria’s provided only little stimulus, we are in Füssen, Germany, has announced Plansee Group is today one of the extremely satisfied. In financial terms, that Josep Planas has been appointed leading global Powder Metallurgy 2012/13 even turned out to be our President and CEO of PMG Indiana companies covering the whole supply second most successful year ever.” As Corporation. It was stated that Ron chain of the high-tech materials based in the preceding year, sales outside Krause, the former President of PMG on molybdenum and tungsten, from of Europe accounted for 52% of the Indiana Corp., will resume new re- ore processing to the production of Plansee Group total (America 31%, sponsibilities within the PMG group. customer-specific components. Asia 21%, Europe 48%). Half of Group Planas has held various positions In the recently announced results sales were achieved in three sectors: in the Powder Metallurgy industry and for the last fiscal year 2012/13, which mechanical engineering, automotive within the PMG group. He has worked ended on the last day of February and consumer electronics. as head of manufacturing and COO 2013, the Plansee Group generated During the last fiscal year, the at PMG Polmetasa S.A.U. as well as consolidated sales of €1.23 billion Plansee Group made investments of being responsible for several success- and employed a total of 5,710 people more than €180 million. This included ful technology transfer projects and a worldwide. Group sales were down additional production capacity in number of complex new launches of 19% on the previous fiscal year with Austria, Germany, the USA, China production lines within the PMG group. the main reason being the sale of the and India as well as the holdings In the US, PMG is currently PMG division (structural PM parts) at in Molymet and recently acquired investing around $23 million to build the end of 2011. PMG had contributed Günther Wirth. The new Plansee High a second manufacturing facility on its annual sales of €200 million. The sales Performance Materials production 40 acre campus in Columbus, Indiana. figures also reflect the customers’ plant in Shanghai is due to start Planas’ wide experience within the cautious purchasing strategies and a production in this summer. Plansee PMG group will help him to realise the fall in the prices of raw materials. spent €29 million on product and planned expansion project success- Dr. Michael Schwarzkopf, Chairman process innovations. fully, the company stated. of the Executive Board of the Plansee www.plansee.com www.pmgsinter.com Group said in presenting the results

Kennametal sees drop in Lower sales at Sandvik AB in sales, but upbeat for coming first half results

financial year Sweden’s Sandvik AB has reported that total invoiced group sales for the second quarter (to end of June 2013) amounted Kennametal, one of the world’s leading cemented carbide to SEK 23,043 million, down 6% on the same period in 2012. and hard material producers reported that final quarter Invoiced sales for the first half of 2013 amounted to SEK sales (April to June 2013) were down 9% to $671 million 45,142 million, down 5%. Operating profit for the first half compared with the same quarter last year. This reflected was reported as SEK 5,518 million (SEK 8,031 million in an 8% organic decline and a 1% unfavourable effect from same period in 2012), with a margin of 12.2% of invoiced currency exchange. Operating income was $91 million, sales. compared with $117 million in the same quarter last year. Market activity for Sandvik Machining Solutions, the “In the June quarter, and for every quarter during largest segment in the group, which includes production of fiscal 2013, Kennametal delivered double-digit profitability cemented carbide cutting tools, remained largely on a par despite market challenges. We demonstrated greater with the first quarter. This segment contributed SEK 14,258 agility in this cycle and elevated our financial perfor- million in sales, down 3%, in the January to June period, mance,” stated Carlos Cardoso, Kennametal Chairman, whilst Sandvik Materials Technology reported invoiced sales President and Chief Executive Officer. of SEK 7,451 million. For the full financial year ending June 2013 Kennametal Sandvik Venture, which includes superhard and hard reported sales of $2.6 billion, compared with $2.7 billion materials based on cemented carbides, cubic boron nitride, last year. Operating income for the financial year was $296 and synthetic diamond, as well as tungsten and tungsten million, compared with $416 million in fiscal 2012. carbide powder producer Wolfram, reported invoiced sales For the fiscal year 2014, Kennametal’s outlook reflects of SEK 2,603 million for the first half 2013. expectations of continued macro-economic improvement, It was decided in the second quarter to form a new with worldwide industrial production building momentum. product area within the Sandvik Venture segment combining The company expects organic sales growth to range Diamond Innovations and Sandvik Hard Materials. The from 5 to 7%, and total sales to grow between 4 and 6% new product area will have approximately 1,800 employees in fiscal 2014. This growth rate is expected to outpace and will bring together resources within R&D, sales and global industrial production by more than double through marketing for superhard and hard materials, stated the company-specific initiatives. company. www.kennametal.com www.sandvik.com

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be included in this group of excellent Growth of companies headquartered in the metro Miba Sinter Detroit area.” Metaldyne The company’s biggest area of investing $7 million business growth came from its powertrain in US expansion segment, where Metaldyne introduced recognised in new technologies “to improve or Austria’s Miba Sinter Group is invest- regional awards support the performance of advanced ing $7 million in the expansion of its and more fuel-efficient engines and plant in McConnelsville, Ohio, USA, transmissions,” stated Amato. Metaldyne LLC has announced that it according to a report in the Morgan Other notable supplier recipients was named one of the fastest growing County Herald. included Borg Warner Inc., American businesses in the Detroit metropolitan “We will be doubling the size of Axle & Manufacturing Holdings Inc., TI area by Crain’s Detroit Business for the our plant by February 2014 because Automotive, Piston Automotive, Lear second year in a row. our existing plant is full now. We have Corp., TRW, Meritor Inc., in addition to The list ranks private and public more equipment arriving in February, automotive OEMs Chrysler Group LLC companies headquartered in the so the plant addition will be completed and General Motors. Detroit metropolitan area, USA, by two by spring. We will also be hiring “We appreciate the acknowledge- factors, dollar revenue growth and another 30 people within the next six ment, which is a testament to our percentage revenue growth over the months, and we will create about 100 culture of continuous improvement past three years. jobs within three years,” stated Steve and commitment to operational excel- Metaldyne exhibited revenue Krise, Site Manager of Miba Sinter lence throughout all of our locations. growth of 59% between 2009 and Group in McConnelsville. All Metaldyne employees work hard 2012, from $630 million to over $1 Miba’s plant primarily supplies every day, and this is a result of their billion. “By focusing our invest- the North American auto industry, efforts,” added Amato. ments in our engine, transmission producing parts for manufacturers www.metaldyne.com and driveline product and process such as Ford, General Motors, technology, Metaldyne has seen Chrysler and Volkswagen. substantial growth,” stated Thomas Amato, Metaldyne’s President and CEO. “We are honoured to once again

GKN plans new regional headquarters for the Americas

GKN Driveline and GKN Sinter Metals will provide additional space for state are expanding their automotive opera- of the art testing and validation equip- tions and moving to a new regional ment along with additional engineering headquarters for the Americas in the design areas for driveline and sinter Detroit suburb of Auburn Hills early metal products. Executive manage- next year. ment teams from both GKN Driveline An artist’s impression of GKN’s new The new site will also house and GKN Sinter Metals will be located 168,000 ft2 facility employees from GKN’s Land Systems in the new headquarters building along and North American Services groups. with various engineering groups and our customers and to the Americas.” Construction of the 168,000 ft2 facility other corporate activities. Chris Franks, President, GKN is scheduled to begin in August on an Robert Willig, President of GKN Sinter Metals Americas, added, “The 11.2 acre site. Driveline Americas, noted that additional space is ideally located Headquartered in Auburn Hills the need for additional space and in close proximity to many of our since 1986, GKN has more than 300 resources has become paramount in global customers and will give us employees at its current 113,000 view of GKN’s substantial growth in access to the additional resources ft2 facility. Employment is expected recent years and the number of major needed to provide our customers with to grow by 50 or more full-time new program launches planned for the world-class precision powder-metal employees in the next three years. Americas. products and allow us to deliver on our GKN Driveline is the world’s leading “GKN has significantly increased corporate vision of providing engi- producer of automotive driveline its engineering resources in the past neering that moves the world.” components and systems including four years and plans to recruit and hire GKN officials also acknowledged constant velocity joint, all wheel drive, even more engineering personnel to the tremendous support provided for trans axle and electric drive systems. support more than 100 new program the project by Michigan Governor Rick GKN Sinter Metals is the world’s launches in the next three years for Snyder’s office, the Michigan Economic half pagelargest RMP ad_Layout producer 1 of 1/21/2013 precision 8:34powder AM Page GKN1 Driveline and GKN Sinter Metals,” Development Corporation and the City metal products. stated Willig. “Our new headquarters of Auburn Hills. GKN’s new headquarters complex facility underlines our commitment to www.gkn.com

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Miba reports Q1 results and looks to Something USA and China for growth

Miba AG, one of Austria’s leading F Peter Mitterbauer takes charge and industry and technology corporations, outlines future goals has reported that despite the highly Miba AG confirmed that F Peter BIG is here! challenging market environment the Mitterbauer began his new role as group held its ground in the first quar- Chairman of the Management Board ter of 2013–2014. Consolidated sales on July 1, 2013. The move, an- in the first quarter (February 1 to April nounced earlier this year, sees F Peter 30) equalled EUR 153.5 million, a de- Mitterbauer succeed his father Peter PM gears manufactured by Miba Sinter cline of some EUR 7.4 million or 4.6% Mitterbauer as head of the Austrian Group Avure Technologies introduces the world of isostatic when compared to the first quarter of technology group. 2012–2013. EBIT was reported at EUR As new Chairman of the Manage- with our customers - products and press technology to TeraPi – the largest, fastest 17.8 million, a drop of EUR 2.4 million ment Board F Peter Mitterbauer is solutions for tomorrow and beyond. hot isostatic press ever! when compared to the previous year’s now responsible for the New Technolo- To push forward our goal of profitable figure. gies Group, Strategy, Human Capital, growth, we need to be close to our Despite the cautiously optimistic Controlling, Innovation & Technology customers and act internationally. TeraPi meets the needs of the outlook of the International Monetary and Communications. “My goal is to That is why I want to win, develop Fund which anticipates global further strengthen the position of the and keep the best employees for growing powder metallurgy market, economic growth of 3.3% in 2013, the Miba Group as a technology group,” Miba.” Mitterbauer is convinced that in the manufacture of larger and development in Miba’s sales markets stated F Peter Mitterbauer. this strategy will make it possible to larger parts, such as impellers, is difficult to predict in the medium The new CEO of the Miba Group achieve the Group’s 2015 goal of EUR term, the report stated. feels that even though the company 750 million in sales. turbines and manifolds, that require Miba stated that it is not relying on has consistently widened its range As of July 1, 2013, the Miba AG larger vessels for the hot isostatic further growth for the 2013–2014 busi- of products in the past years, it is Management Board will have a total of ness year as a whole, but is expecting still too often viewed as a classic four members. In addition to F Peter pressing portion of the process. noticeable recovery in the longer term automotive industry supplier. “At 40%, Mitterbauer, Wolfgang Litzlbauer is particularly in the USA and China, the passenger vehicle sector is still now Vice Chairman of the Manage- where the company plans to invest the main contributor to total sales ment Board, responsible for the Miba Until now, size of the parts has been more than EUR 30 million in additional and remains the company’s mainstay, Bearing Group, the Miba Friction limited by long forging cycles and production capacities at its China site however, other business areas such as Group, the Miba Coating Group and over the next few years. In the USA, construction equipment, energy (power Purchasing, while Harald Neubert international shipping constraints. the Company is preparing for another plants, power transmission) and the heads up the Miba Sinter Group and Today, with the innovative on-site major order from the North American production of special machinery are is also responsible for central quality construction equipment industry. becoming more and more important.” assurance. The latest member is vessel and frame assembly offered Investments are also planned for Mitterbauer claims that interna- Markus Hofer, who as Chief Financial with TeraPi, these hurdles are the sites in Austria, with a new input tionalisation, innovation and tech- Officer is responsible for Corporate removed – while offering improved stock production line for bearings in nology are at the top of his priority list. Finance, IT and Business Excellence. Aurachkirchen. “We develop - also in close cooperation www.miba.com loading, reduced cycle time and reduced cost per kilo.

CIP-COLD-ISOSTATIC-PRESSES G WET BAG PRESSES G DRY BAG PRESSES Download a FREE presentation at LABORATORY PRESSES www.avure.com/big since 1917 PISTON EXTRUDER G LOOMIS PRODUCTS Kahlefeld GmbH CONTINUES PISTON EXTRUDER G PISTON EXTRUDER 16 T - 500 T LOOMIS PRODUCTS COMPANY Download our presentation on the next- CONSULTATION AND COMPLETE PLANT DESIGN generation customizable HIP and discover this uy the TOOLING game-changing technology for yourself! b orig inal · buy quality Stockwiesen 3 · 67659 Kaiserslautern/Germany · Tel +49 (0)6301-79999-70 · Fax +49 (0)6301-79999-92 · [email protected] · www.loomis-gmbh.de The Global Leader in Isostatic Processing 14 Powder Metallurgy Review Autumn / Fall 2013 © 2013 Inovar Communications Ltd © 2013 Inovar Communications Ltd Avure Technologies,Autumn 210 Gothic / Fall Court, 2013 Franklin, Powder TN 37067 Metallurgy USA Tel: +1 614 Review 891 2732 15

GT Advanced Technologies MaterialsScience acquires Thermal Technology LLC

GT Advanced Tech- nologies, headquar- Acrawax® C tered in Nashua, New Hampshire, USA, has Lubricant announced that it has acquired California based Thermal Tech- nology LLC. Founded some 60 years ago, Thermal Technology develops and sells a wide range of high temperature thermal and vacuum This spark plasma sintering furnace products used in the was manufactured by Thermal fabrication of advanced Technology materials. GT has acquired several key products and technologies that will allow it to address new markets with a range of production equipment options. This includes annealing technology that the company believes will be important in the manufacturing of sapphire cover screens; crystal growth technology based on the Kyropoulous growth method and edge defined film growth (EFG) technology for large surface area sapphire. The company has also acquired Spark Plasma Sintering (SPS) technology, which allows dense ceramics to be obtained under uniform heating at relatively low temperatures and in short processing times. The SPS technology is expected to have a wide range of applications including with medical applications, sputtering targets, space applications and thermoelectric convertors for hybrid electric cars. “The acquisition of the Thermal Technology business Metal Powder Lubricants adds a number of innovative and important products Setting the Standard for Excellence and technologies to our rapidly diversifying portfolio that will, we believe, allow us to accelerate our entrance into Acrawax C® Lubricant has been the benchmark for excellence new markets,” stated Tom Gutierrez, GT’s president and in the metal powder industry for over fifty years. This clean- CEO. “The acquisition expands our served markets and burning lubricant generates no metallic or corrosive by- complements several of our current product lines. “ “This is an exciting moment for the company, our products, which can contribute to environmental emissions employees and our customers,” stated Matt Mede, Presi- and furnace corrosion, and is available in a variety of custom dent and CEO of Thermal Technology. “The acquisition particle sizes. will open new opportunities for growth for our products and technology as we integrate them into GT’s business Other features and benefits of Acrawax® C Lubricant include: operations. Leveraging GT’s leadership in engineering and product development and their strengths in low-cost – 100% metal free global supply chain management will accelerate the time- – Combustible, leaving no residue on sintered parts to-market of our technology to drive market adoption in several promising markets as we go forward. Customers – Excellent, free-flowing powder mixes will also benefit through GT’s global service and support – Low die wear and easy part removal from the die capabilities.” – Reduced part distortion www.gtat.com www.thermaltechnology.com Contact a Lonza representative to learn more: E: [email protected] T: 800 777 1875 www.lonza.com

SEI, which includes the production of cemented carbides covering carbon brushes are today Japan’s leading PM (hardmetals), PM parts, and the fully owned A.L.M.T. Schunk Group celebrates its 100th produced in the Group’s Materials subsidiary which produces W, Mo, heavy metal, thermal Division along with technical ceramics, companies helped by management materials, ceramics, diamond tools and Jubilee pantograph contact strips, etc. devaluation of Yen hardmetals, reported a 4.4% increase in division sales The Powder Metallurgy products to Yen 72.2 billion ($740 million). Sales of structural PM The Schunk Group, with its head- the world. This is also evident in the are produced at three main plants in The 20% devaluation of the Japanese Yen against the US parts increased by 3.3% in the quarter to Yen 12.2 billion quarters in Heuchelheim, Germany, extraordinarily strong loyalty our the Schunk Sinter Metals Division, Dollar since the end of 2012 has resulted in a much im- ($125 million), whilst hardmetal (cemented carbide ) sales celebrated its 100th Jubilee in August employees have to the company.” two of which are located in Thale and proved business environment for many Japanese compa- increased by 7.1% to Yen 19.5 billion ($199.8 million), and with its approximately 8,300 employees Schunk sees its large investments Giessen, Germany and another in nies, including those in the PM industry. sales at A.L.M.T. increased by 10.3% to Yen 9.6 billion at more than 60 locations worldwide in its facilities, which the company Mexico. Thale specialises in larger PM Mitsubishi Materials Corp. (MMC) reported an increase ($98.4 million). joining in the celebrations. makes all over the world, as also parts produced on powder presses of 16% in consolidated group net sales for the first quarter SEI launched its new mid-term management plan in The company was founded by being an investment in and for the ranging from 150 to 1500 metric of its new financial year (2013/2014) ended June 30 to Yen April 2013 called VISION 2017 which aims to match last Ludwig Schunk and Karl Ebe as employees. “With a great deal of tonnes force and also Metal Injection 423 billion ($4.4 billion). This is largely due to the 13.5% year’s record earnings or to reach even higher levels Schunk & Ebe in Fulda in 1913 for commitment and creativity, our Moulded parts, whilst the PM plant in rise in cement sales and a 13.8% rise in sales of the metals through prior investments in capital assets and research the production of carbon brushes for employees have continually devel- Giessen produces smaller PM parts, division. MMCs ‘Advanced Materials & Tools’ division, and development in the sectors covered by its divisions. dynamos and engines. After Karl Ebe oped Schunk into what it is today, a PM bearings and sintered filters with which includes Diamet Corp, Mitsubishi Materials Tools VISION 2017 targets consolidated sales of Yen 3 trillion, passed away, Ludwig Schunk led the successful globally operating tech- powder press capacity up to 150 tons. Co., Ltd. and MMC Superalloy Corp, continued in negative operating income of Yen 180 billion and ROA of 9% by the company successfully until his death in nology corporation. The many exciting The Schunk Sinter Metals Division territory in the quarter with a 1.7% decrease in sales to Yen financial year ending March 2018. 1947. In his will Ludwig Schunk stipu- jubilee events being held this year at contributed around €140 million to 36 billion ($369 million). However, operating profit for the The ‘Industrial Materials & Others’ division is reported lated that the company be preserved all our facilities are first and foremost Group sales of €930 million in 2012. Advanced Materials & Tools division increased by 15.1%. to have spent Yen 6.8 billion ($70 million) in R&D over the as a Foundation for the employees, a way of thanking all our staff,” says The Schunk Group recently There were reported increases in sales for cemented past year. The division plans to increase sales of cutting and the Ludwig-Schunk-Stiftung e.V. Federer. reported that Gerhard Federer, CEO of carbide tools as a direct result of the depreciation of the tools to newly emerging markets such as Brazil, Indonesia Foundation was established. In the hundred years since its the Schunk Group, will retire from his Yen, but sales of PM parts decreased due to the end of and Turkey. SEI recently started full-scale production at “Ludwig Schunk’s will still shapes establishment, Schunk & Ebe has position with effect from October 31, eco-car government subsidies in Japan. its new hardmetal factory in Hokkaido where Hokkaido our corporate culture,” stated CEO become a globally operating corporate 2013 due to health reasons. He will be Sumitomo Electric Industries (SEI) also reported Sumiden Precision Co Ltd has introduced super high- Gerhard Federer. “It obliges us to group with four divisions; Schunk succeeded on November 1, 2013 by Dr buoyant first quarter sales to June 30 with an 11.4% efficiency production lines to meet global demand for continually develop and maintain the Materials, Schunk Sinter Metals, Weiss Arno Roth, a long-time member of the increase to Yen 587.4 billion ($6.02 billion). Group net hardmetal tools. These production lines have doubled company’s independence. Our busi- Group (environmental simulation Management Board who is currently income improved by 13.8% to Yen 15.9 billion ($163 output per employee and increased productivity per unit of ness strategy geared towards long- and climate technology) and Schunk responsible for the Weiss Group and million). The ‘Industrial Materials & Others’ division at space by 30%. Production lead times for cemented carbide term growth makes Schunk a secure Sonosystems (ultrasonic joining tech- Sonosystems divisions. indexable inserts have been halved from previous levels to and attractive employer throughout nology). The original product range www.schunk-group.com 6 days. In the sintered parts sector SEI has established a manufacturing and marketing joint venture with WLK Group and Santini Group, both industry leaders in Your Vacuum Sintering Solution Indonesia. SEI states that it is committed to developing new PM products using soft magnetic iron powders which Precise ◊ reliable ◊ efficient have excellent magnetic properties in the high frequency range, as well as high performance soft magnetic powder materials to support EV and HEV applications. A.L.M.T. is also accelerating new product development and marketing in the electronics field, including precision diamond tools for semiconductor nano- and micro- processing. The company has developed a high-hardness nano-polycrystalline diamond made from ultra-fine grains of several tens of nanometers using a new ultra-high voltage technology and a proprietary new manufacturing process. The SEI Group is also developing technology for recycling of tungsten and cobalt powders. Hitachi Chemicals Ltd reported that sales in its ‘Functional Materials’ and ‘Advanced Components & Sinter-HIP System Systems’ divisions increased by just 1% to Yen 119 billion ($1.2 billion) for the quarter ending June 30, 2013. Sales ials in the Advanced Components & Systems division, which mater ntaCt Suppliers of metal powders to the PM Industry includes structural PM parts and PM bearings, decreased MIM System Co als ◊ since 1945 by 2.2% to Yen 53.7 billion ($550 million) compared with met the same quarter in 2012. The decrease was attributed tory fraC Phone US: +1 (951) 270 - 3960 to a decline in sales of industrial batteries and systems. re als ◊ Phone DE: +49 (641) 68 690 - 142 However, operating income for the two divisions at Hitachi met E-Mail: [email protected] Ronald Britton Ltd, iCs ◊ Home: www.pvatepla.com Chemicals increased by 10.6% to Yen 7.5 billion ($76.9 eram Regent Mill, Regent Street, l ◊ C Rochdale, United Kingdom million) in the quarter. rdmeta Tel: Ha +44 (0)1706 666 620 Cert No. 9125 ISOCert. 9001, No. ISO 9125 14001 web: www.ronaldbritton.co.uk ISO 9001 ISO 14001 Driven by German enGineerinG culture

desired properties for applications Dion Vaughan appointed Chief Executive within a variety of industries including Changes in SMS Meer’s of specialist metal powder producer automotive, marine, electronics, clean supervisory and managing energy and aerospace. Metalysis Tony Pedder, Chairman of Metalysis boards commented, “The company has Metalysis, the UK based specialist coming years. The powders produced performed well on its science and SMS Meer has announced that with effect from July 1, 2013, metals producer, has announced the by the Metalysis process, states the technology goals, which has enabled Heinrich Weiss, who has been responsible for the development We’ve got what it takes appointment of Dr Dion Vaughan as company, will dramatically change the Board and shareholders to develop and leadership of the group of companies for the last 45 years, to outperform our Chief Executive. He succeeds Guppy the production of high value titanium a new scale-up plan for the business. will be resigning from his post on the Managing Board and will competition and we’ll Dhariwal who is retiring, having joined components both utilising existing This plan, based on simpler and assume the Chairmanship of the Supervisory Board. The pre- the firm in 2010. Dion is a trained manufacturing techniques and driving cheaper production cells, is a longer sent Chairman, Dr Manfred Bischoff, will become a Member of prove it with a FREE metallurgist and has worked across forward the adoption of 3D print in term plan and so it is a natural time the Supervisory Board. TRIAL RUN IN FULL SIZE the metals, mining and investment specialist metal products. for Guppy, who has done a very good Dr Joachim Schönbeck, who is already a Member of the PRODUCTION FURNACES sectors including Hatch Corporate In addition, this new technology has job in re-organising the company, to Managing Board, will be appointed to represent the Company BEFORE PURCHASE! Finance, Sheffield Forge Masters and the potential to significantly reduce hand over to Dion Vaughan to deliver externally with effect from July 1, 2013. Jointly with his JP Morgan. the cost of specialty metal powder an exciting future for Metalysis.” colleagues, Burkhard Dahmen and Eckhard Schulte, he will Metalysis has developed an entirely production. This means previously Dr Vaughan added, “Our future continue to constitute the Management of SMS GmbH. Elnik Systems puts more new way of producing high value expensive metals such as titanium can emphasis will be on further devel- Dr Joachim Schönbeck will be primarily responsible for SMS cutting edge technology into our metal powders that reduces the cost be used in a variety of new applications oping our strength in science and Meer as before, Burkhard Dahmen will be responsible for SMS debind and sintering equipment and environmental impact of metal to satisfy the latent demand for a low technology, where the company Siemag (including the Paul Wurth majority holding) and Eckhard so you get more quality and production as compared with existing cost, light weight, high strength and has historically performed, and on Schulte will be the CFO of the group. cost-efficiency out of it. processes. The Metalysis technology is corrosion resistant metal. partnering with leading metals compa- www.sms-meer.com able to transform metal oxides, such The nature of the Metalysis process nies who can help with engineering as ores directly into metal powders in means that it can produce alloys that scale-up and market adoption. The a single step. It is currently focusing would not be cost effective by tradi- company is already making good on the high value specialist metals tional processes. It is entirely solid- progress in exploring such partnering Carpenter names new leader titanium and tantalum. state; therefore metals with signifi- arrangements”. As a result Metalysis believes cantly different densities or melting www.metalysis.com of Performance Engineered that it can play a critical role in two points can be alloyed. These innovative Don’t take our word manufacturing revolutions over the alloys can be tailored to have the Products division for it. Let the results speak for themselves. Carpenter Technology Corporation has named Gary Heasley

as the company’s new Senior Vice President - Performance Engineered Products (PEP). As of Monday July 22, Heasley will Call uS today! have responsibility for Carpenter subsidiaries Amega West INSTITUT DR. FOERSTER GMBH & CO. KG Services, LLC, Dynamet, Inc., and Carpenter Powder Products, Inc. He will also oversee Carpenter’s distribution businesses, Latrobe Specialty Steel Distribution, Inc. and Specialty Steel Supply, Inc. The PEP portfolio accounts for approximately $600 million in annual sales, or 25% of Carpenter’s total annual ® revenue. KOERZIMAT HcJ and MS Heasley joins Carpenter after eight years with Steel Dynamics, Inc. (SDI), an $8 billion Fort Wayne, Indiana-based For the determination of company for which he most recently served as Executive Vice President, Strategic Planning and Business Development, • Coercive field strength HcJ and President of Steel Dynamics’ subsidiary, New Millennium • Energy efficient, uses • Saturation magnetization σ Buildings Systems. Prior to joining Steel Dynamics as its CFO s in 2005, Heasley spent three years as Senior Vice President less process gas, and Manager, Metals Group for KeyBanc Capital Markets, Inc./ electricity and handling time McDonald Investments. • Process any metal with any binder In addition to SDI and KeyBank Capital Markets, Inc./ McDonald Investments, Heasley held corporate finance posi- • Process in H2, N2, Ar or Vacuum tions with Nakornthai Strip Mill Public Company Limited and Ernst & Young, LLP. www.cartech.com

107 Commerce Road | Cedar Grove, NJ 07009 USA www.foerstergroup.de ipmd.net +1.973.239.6066 | [email protected] Sign up for our free e-newsletter at: www.elnik.com In Laisen 70 · 72766 Reutlingen · Germany · Phone +49 7121 140-312 · Fax +49 7121 140-280 · [email protected] www.ipmd.net/enews

Abtex offers deburring Increasing use of electric system for Powder motors in automotive The POWDERS that Metallurgy parts applications could provide

Abtex Corporation, based in boost for powder magnets New York State, USA, includes A recent study by IMS Research predicts that DC brushless make the PRODUCTS in its range of Tri-Ten deburring systems a unit specifically motor shipments will outpace shipments of DC brushed and From the global leader in P/M and MIM powders suited to the deburring of green stepper motors used in automotive applications from 2012 to Powder Metallurgy (PM) parts. 2017. The U series deburring DC brushless motor shipments are expected to increase system deburrs both sides by 52% over the 5 year period to reach more than 462 million of a part in a single pass and units. This compares with 30% growth for brushed DC motor is designed for applications shipments for the same period. These predictions were requiring a small footprint and published in the 2013 edition of the ‘Electric Motors in Auto- Take innovation to the next power with AMETEK, the portability. motive Applications’ market study issued by IMS Research leader in powder metallurgy since 1970. Parts are loaded at one earlier this year. The Tri Ten U Series has end and a magnetic conveyor wheels for portability and passes them through an offset Whether you’re producing components for automotive, deburrs both sides of planetary deburring head aerospace, medical, marine or lock hardware applications, green powder metal parts where three fibre abrasive brushes deburr the upward AMETEK Motor Vehicle Series, P/M Stainless, MIM, facing surface. Ultra Stainless and Titanium powders can be custom The conveyor then carries the part to a mechanism that flips it on to a parallel, magnetized conveyor that formulated to your exact specifications. transports the part back through the planetary head and deposits it at an opening next to the entrance. Regardless of the volume and properties you require, www.abtex.com AMETEK has the ideal solution. Using proprietary methods for manufacturing superfine metal powders and roll-compacted powder, there’s a formulation World market for electric motors in automotive applications that’s right for you. (Source IMS Research)

Powertrain and chassis applications in cars have the Our powder allows you to provide innovative products highest usage rates for DC brushless motors. The predomi- nantly mechanically driven applications such as power that add value to your existing capabilities, help you steering, transmission actuation and engine cooling systems develop new markets, and meet your customers’ are becoming increasingly electrically-driven, causing the number of DC brushless motors used in these applications to unique needs. increase proportionately. DC brushless motors offer longevity and power density, qualities that are essential for use in powertrain and chassis applications where there is limited space and frequent motor operation is required. “Although brushed DC motors account for a majority of the motors used in automotive applications, there is relatively less growth potential for brushed DC motor shipments,“ stated Innovative & Advanced Metallurgical Technology Bryan Turnbough, Small Motors Analyst at IMS Research. “On the other hand, DC brushless motors are being used in P.O. Box 427 • Route 519 areas that are relatively new for electric motors in automotive Eighty Four, PA 15330 USA applications, and that have been growing rapidly in recent Tel: +1 724-250-5182 • Fax: +1 724-225-6622 years. Increasing sales of plug-in electric vehicles, which have powertrain and chassis systems that are electromechanically- www.ametekmetals.com driven, are expected to provide greater growth potential for brushless DC motor shipments than for brushed DC motors.” It is generally recognised that an increasing number of new DC brushless electric motors are manufactured using powder magnetic circuits comprising a soft magnetic core made from bonded iron powder, and permanent magnets made from NdFeB magnets. www.imsresearch.com

Japan Powder Metallurgy University of Trento successfully hosts 2014 PM World Association elects new EPMA’s 2013 PM Summer School Congress set for

president The University of Trento hosted the facilities and as part of the practical Orlando, USA latest EPMA Powder Metallurgy Sum- side of the event the students visited The Japan Powder Metallurgy mer School, which took place 8 - 12 two companies; Mimest, who produce The 2014 World Congress on Association (JPMA) announced July 2013 in Trento, Italy. The annual typical MIM parts, and Eurocoating, Powder Metallurgy & Particulate at its General Assembly that Mr summer school, organised by the Eu- a company working in biomaterials. Materials – PM2014 will take place Tetsuo Ito of Hitachi Chemical Co ropean Powder Metallurgy Association, Participants also received complemen- at the Walt Disney World Dolphin Ltd will take over as President of provided 52 students from a variety of tary copies of both Powder Metallurgy Hotel, Orlando, Florida, USA from the association from Mr Kazuyoshi academic and industrial backgrounds Review and PIM International. May 18–22 2014. Tsunoda. with an introduction to PM by a num- Joan Hallward, Summer School Organised and sponsored by the The JPMA also reported a ber of highly regarded academics and Coordinator stated, “This year’s Metal Powder Industries Federation number of changes to its board industrial lecturers. Summer School programme has (MPIF) in cooperation with APMI at the General Assembly held on Mr Tetsuo Ito is the new Professor José Torralba from the benefited from the University of Trento’s International, PM2014 will be the May 23. president of the JPMA Universidad Carlos III de Madrid, superb laboratory facilities and well most important international PM www.jpma.gr.jp coordinated the event in conjunction located hotels. No Summer School event of the year. with Professor Alberto Molinari and his would be complete without the Summer Along with an all topic technical team from the University of Trento. School dinner and song contest, where programme a number of special Lectures were complemented by everyone sang to their heart’s content.” subject areas have been identified High purity carbonyl nickel the University of Trento’s laboratory www.epma.com for special interest programs, these include: powders within specific • NDT/Failure Analysis size ranges offered by Hart • Machinability • Fatigue Materials • Technologies for PM Growth. A major trade exhibition will Hart Materials Limited, a UK based supplier of metallic and also feature international suppliers composite particulate materials, is now offering a range of of metal powders, components, high purity carbonyl-based nickel powders within specific equipment and related services. size ranges, currently not available in the market place. www.mpif.org Dr Tony Hart, Chairman of Hart Materials Limited, told AMERICAN ISOSTATIC PRESSES, INC. Powder Metallurgy Review, “About four years ago the number Participants at the EPMA 2013 PM Summer School The HIP Industry Innovators of grades of carbonyl nickel powders available commercially was reduced to two specific products, one spherical powder * HIP - Hot Isostatic Presses and one filamentary product. Although these powders * CIP - Cold Isostatic Presses are very high quality materials the particle sizes currently * High Temperature Furnaces * Computer Controls available are not necessarily ideal for all applications. Hart * Temperatures to 2200 C Materials Limited has therefore developed technology to * Pressures to 4000 Mpa the separate different size fractions from the basic spherical Enhancing Performance * Thermocouple Sales * Research and Production powder.” * New and Used Systems As a consequence the company is now able to offer three different size grades: of metals and materials • > 44 microns • < 44 microns > 20 microns • < 20 microns The company states that products can be supplied with accurate particle size details and a basic chemical analysis. Further developments are in hand to produce an even finer grade with 100% of particles below 15 microns. Dr Hart is a former employee of what was the Interna- tional Nickel Research Laboratory in Birmingham, UK, and has a sound appreciation of the advantages of carbonyl nickel powders. Dr Paul Lansdell, who has been heading up the development project, graduated in metallurgy at Birmingham University and was later awarded his Doctorate in electro- Controlled shot peening | C.A.S.E Superfinishing | Laser peening | Engineered Coatings | Analytical services chemistry by the same establishment. www.hartmaterials.com Over 70 international divisions and on-site processing worldwide

1205 S. Columbus Airport Road Columbus, Ohio 43207 www.cwst.co.uk PH: 1-614-497-3148 [email protected] +44 (0) 1635 279621 A business unit of Curtiss-Wright Surface Technologies AIP FX: 1-614-497-3407 www.aiphip.com

The app, currently available in Apple accordance with the requirements of The digital AM production method, Hoeganaes iOS format, also includes a selection the French Markets Authority. New Additive Manufacturing system by contrast, saves a lot of time, as the of extended abstracts from technical Phenix Systems designs and design for the RPD is ready in around launches papers presented by Hoeganaes, manufactures proprietary Direct Metal for 3D printing of removable partial 15 minutes. Due to the flexibility of smartphone app details of key regional contacts, 3D Printers that print chemically pure, dentures design possible with Direct Metal and a list of industry events that the fully dense metal and ceramic parts Laser-Sintering (DMLS), the manu- EOS GmbH recently showcased a new 2012 RPD module from 3Shape. The Hoeganaes Corporation, a world lead- company is scheduled to exhibit at. from very fine powders with a parti- facturing process does not restrict Additive Manufacturing (AM) process at resulting virtual model is sliced and er in the production of atomised steel The app can be download from the cle size ranging from 6 to 9 microns. the capabilities of the modelling the IDS 2013 (35th International Dental the digital information is utilised to and iron powders based in Cinnamin- Apple itunes store. Materials include stainless steel, tool software. High strength, rigid parts are Show), Cologne, Germany, for produc- direct a focussed laser beam to fuse son, New Jersey, USA, has recently www.hoeganaes.com steel, super alloys, non-ferrous alloys, produced. ing removable partial dentures (RPD). metal powder in successive layers launched a free app that brings the precious metals and alumina for a The production of RPD’s via DMLS The technique uses 3D data sourced until the prosthesis is complete. company’s product data sheets directly variety of aerospace, automotive and is very accurate, making laboratory directly from the patient’s mouth as the For a dental laboratory, the conven- to a user’s smartphone or tablet. patient specific medical device ap- work easier. The denture is produced basis for the manufacturing process. tional manufacture of cast prostheses The app includes data sheets for plications. to an accuracy of ± 20 µm and is of a Data created by intraoral scanners involves a lot of work. The preparation the company’s Ancorsteel, Ancorbond, “Phenix Systems is a strategic and consistently high quality. Around 48 3D Systems or from scanning an impression or of a cast model and subsequent wax Ancorloy and differentiated addition to our extensive units can be produced within 24 hours, model is processed without any loss of modelling often takes more than an Distaloy range completes 3D content-to-print portfolio and we corresponding to an average build time accuracy using the customised soft- hour and the entire casting procedure of products, are thrilled to deliver these powerful of around 30 minutes per unit, making acquisition of ware functions of the new CAMbridge including finishing is time-consuming. allowing the solutions to our customers,” stated the process economical. user to see alloy Phenix Systems Avi Reichental, President and CEO, 3D RPDs are made in the established compositions, Systems. “Our proven track record in EOSINT M 270 machine from EOS. flow rates, 3D Systems based in Rock Hill, advanced manufacturing, combined Certified for use in the dental industry compaction South Carolina, USA, has completed with Phenix Systems extensive metals (CE 0537), EOS CobaltChrome RPD pressure data its acquisition of Phenix Systems, a technology and expertise represents a is the powder metal used. It is a fine and more. leading global provider of Direct Metal true game-changer that empowers our grained, biocompatible material free Selective Laser Sintering 3D Printers customers to manufacture the future.” from nickel, beryllium and cadmium. The Hoeganaes based in Riom, France. The company www.3dsystems.com Its mechanical properties including app provides data paid $15.1 million for 81% of the share density, resilience and elongation at on a range of capital and will seek to purchase the break satisfy the requirements of the products remaining shares and voting rights in Typical removable partial dentures Laser sintering in action producing standard EN ISO 22674:2006 Type 5. crowns and bridges www.eos.info

rhenium powder processing before Ipsen and ExOne collaborate European Powder Metallurgy being appointed CEO of Erasteel in to offer complete 3D printing Association elects new President 2007, and then Aubert & Duval in 2009. Here he maintained a strong focus solution The European Powder Metallurgy As- cial result in 2012. “We are looking on superalloys and high-speed steel sociation (EPMA) has announced that forward to further growth in both powders as well as hipped parts. The ExOne Company, a manufacturer of three dimensional Philippe Gundermann, CEO of Aubert the PM industry and the association, Retiring President Ingo Cremer Isostatic Presses printing machines and printed products, is collaborating et Duval, has been elected as the as- where we will be assisted by the newly was elected in 2007 as the fourth ProductionCIP: dia 1m,200 MPa ProductionHIP:2000°C,200MPa with vacuum furnace manufacturer Ipsen to provide cus- sociation’s new President. Some 30 launched European Additive Manufac- President of the EPMA following Cesar tomers with a complete 3D printing package. member companies met in Munich on turing Group (EAMG),” he stated. Molins, Lothar Albano-Müller and Per ExOne expects its collaboration with Ipsen to strengthen May 3 2013 for the association’s 24th The EPMA Council was re-elected Lindskog. the level of support offered to customers throughout the Annual General Assembly. with two changes. Dr Rainer Link, www.epma.com entire development and production process. Together At the General Assembly retir- GKN Sintermetals, replaces the companies will provide a packaged turn-key solution ing President Ingo Cremer, Cremer the retiring Volker Arnhold, for customers, Thermoprozessanlagen GmbH, pre- and Jody Turin, Bodycote enabling them to sented a review of the last six years AB, joins the Council as the materialise new of his presidency. Gundermann then new representative for the concepts, designs, concluded, “We would like to thank HIP sector. Peter Kjeldsteen, prototypes and Ingo Cremer for his work on behalf Sintex A/S, was elected to production parts of EPMA over his last two-terms as take over as Treasurer. with virtually President against some very difficult Gundermann started unlimited design external conditions.” Gundermann also his career in metallurgy 20 complexity. outlined his vision for the future direc- years ago in the non-ferrous David J Burns, tion of the EPMA. sector, joining the ERAMET ExOne’s President Engineered Pressure Systems Int. N.V. Jonathan Wroe, EPMA Executive Group in the area of cobalt and COO, stated, Walgoedstraat 19, B 9140 Temse, Belgium Director, gave an update of the EPMA’s powder production. As “As our pipeline Tel : +32 (0)3 711 64 24 activities over the past twelve months, CEO of Eurotungstene he of opportunities The ExOne M-Print system selectively reporting that the EPMA had a stable developed knowledge in Retiring EPMA President Ingo Cremer with new [email protected] www.epsi-highpressure.com is building we dispenses chemical binder into thin layers For customers in North America, please contact : membership base and produced a hardmetal technology and President Philipoe Gundermann and former have simplified of powdered metal EPSI-Haverhill, MA Tel : + 1 978 469 82 80 better than anticipated positive finan- cobalt, copper, nickel and President Cesar Molins the purchasing process for 3D printers by offering a complete printer- furnace package. Ipsen is ideal for us to collaborate with given their industrial focus and global presence.” “As technical experts dedicated to lean manufacturing, Ipsen was chosen due to our industry wide reputation for custom innovations and forward thinking research and development focus,” stated Mark Heninger, Ipsen’s Vacuum Product Manager. “We are excited about this collaboration, and the opportunity to pool our knowledge with ExOne to provide a reliable solution for customers.” ExOne builds 3D printing machines at its facilities in the United States and Germany. ExOne also supplies the associated products, including consumables and replace- ment parts, and services, including training and technical support, necessary for purchasers of its machines to print products. Ipsen has production locations in Europe, America and Asia, along with representation in 34 countries. The company designs and manufactures industrial vacuum furnaces, atmosphere furnaces and supervisory control systems for a wide variety of thermal processing markets. www.exone.com www.IpsenUSA.com

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Höganäs Digital Metal® produces highly complex and intricate designs with 3D printing

Fig. 1 The cost benefits of additive manufacturing In November 2012 Swedish metal Fig. 4 A typical CAD file as used in the Fig. 5 Schematic of the build box that shows the potential to build a large number of powder producer Höganäs AB acquired Additive Manufacturing process components in a single process fcubic AB as part of the company’s vision to broaden the application of or CAD file. The 3D file is prepared and The process is flexible since shape for prototype or series produc- powder technology. The acquisition sliced into 2D files corresponding to a forming and sintering is done in tion for various market segments included primarily patents, expert 45 micron powder layer. A layer of 45 separate steps with different equip- including non-critical components in knowledge and a first generation 3D micron powder is applied in the build ment, which means that the forming the aerospace and medical sectors. printer for metal components. The box and the printer passes over the step can be maximized. Examples of different components company name was then changed to surface and puts ink on relevant spots manufactured by Digital Metal® Digital Metal AB. A process line has based on information from the 2D file. Markets technology are shown in Figs. 6 to 8. since been built up in Höganäs for This is repeated layer by layer until Höganäs states that its Digital Metal® www.hoganas.com production with 3D technology and the component is formed in accord- technology is most suitable at present a second generation 3D printer is ance with the original 3D file. Building for small components of complex currently being commissioned. time is currently in the region of one Digital Metal AB, states Höganäs, cm per hour, however it takes just as offers a revolutionary and innovative long to print the build box whether it manufacturing technique for metallic contains one component or is full of ® components. It is a proprietary tech- Fig. 2 Overview of the Digital Metal process components. nology for the Additive Manufacturing Finishing after printing includes the and 3D printing of metal components cleaning of components from powder and systems and offers the unique residue and sintering to achieve capability to cost effectively produce the final size and strength. Surface highly complex and intricate designs roughness after sintering is normally and features for metallic parts. Ra 6 but can easily be improved Additive Manufacturing is the with traditional surface treatment process of building components in processes to Ra 3 or better. layers directly from 3D CAD data, ® without the need of complex and costly Benefits of Digital Metal technology tools and with minimal waste material. Printing is done at room temperature The technology is currently in the with Digital Metal® technology without process of moving from a focus on the partial melting of the powder particles, Fig. 6 Very high resolution is possible to obtain with Digital Metal® technology. Minia- production of prototypes to the rapid which occurs with competing laser tures of the old salt glazed pottery Jars were produced for Höganäs’ annual meeting in manufacturing of series components. or electron beam technology. This Fig. 3 Schematic of the Digital Metal® printing process 2013. Surface conditions are Ra 6 as sintered or Ra 1 as super finished Whilst most of the revenue derived provides high tolerances, a high level from the technology to-date can be of surface finish and very high levels of • Easy customisation - multiple 3D treatment steps. Another cost attributed to production of plastic detail. The technology offers toler- files can be handled simultane- difference with Additive Manufacturing parts, the production of metal parts ances of 100 microns, with holes and ously corresponding to multiple is that the process is, in general, by 3D printing is becoming more and wall thicknesses currently down to 200 customer needs. not restricted by shape complexity, more viable. The main methods for microns. unlike conventional technologies. Additive Manufacturing of metal parts The graphs in Fig. 1 show sche- Cleaning of printed components is The more challenging the shape, the include laser or electron beam melting matically the cost benefit of Additive facilitated by the formation occurring more advanced the tool has to be in or precision ink-jet processing on a Manufacturing. The initial start-up at room temperature. Furthermore, order to make a part with conventional powder bed. The advantages of 3D cost for conventional production is, there is in principal no need to processes. This has a substantial technology are primarily; in general, high due to tooling or the build a support structure during setup of CNC machines, however the impact on cost development. printing because the components are Fig. 7 The advantages provided by Digital Fig. 8 The design freedom offered by this • Free forming capability with few cost per component will be reduced supported by the powder bed in the Metal® have been used to produce technology enables design for function. design limitations with volume production. 3D printing The Digital Metal® process build box. The whole volume of the lightweight fasteners from 316L stainless These sensor housings, with pressure • Fast time to market - only a 3D only needs a CAD file to start produc- Höganäs’ Digital Metal® system is build box can therefore be maximised steel. The threads are printed without any membrane and threads, are printed file is needed to create a prototype tion providing a low initial cost. Some based on precision ink-jet printing on and the components can be packed additional machining. The hollow interior simultaneously with no post machining • Low initial cost as there is no cost improvements can be achieved a powder bed. Components are built tightly because no account of thermal structure would be very challenging to tooling with volumes due to improved post up layer by layer from an original 3D conductivity needs to be taken. produce with conventional technology

In the 1990s North America’s Powder Metallurgy industry enjoyed rapid growth thanks to a dramatic increase in the quantity and weight of PM components used in US automobiles. The recession of 2008, a drive towards smaller and more fuel efficient vehicles and the globalisation of engine and gearbox development has however dramatically changed the landscape for the region’s PM producers. Eric Boreczky reviews the recent history of PM in North America and considers the challenges that lie ahead in adapting to a changing automotive market.

Over the last fifty years the North meet new PM application performance of PM parts per vehicle on average, Production of complex sintered parts of con- Quality unites – a fact that our customers and American Power Metallurgy (PM) targets. These new applications, and with some vehicles containing over industry has evolved from a low cost the efforts to improve existing parts, 34 kg (75 lb) of PM content. Current sistently high quality on cost-effective terms – we discover time and again with every new metalworking technology producing has helped to grow the industry from applications include dozens of critical those are the demands made on modern project. Together we develop solutions that simple parts (based on today’s 3-5.5 kg (7-12 lb) of PM content per engine, transmission, driveline and powder presses. SMS Meer has played a lead- give our partners the competitive edge in their standards) to a multi-billion dollar vehicle to a North American vehicle chassis applications. ing role in the further development of the business. Thanks to this good cooperation, industry producing highly complex today containing nearly 20 kg (45 lb) The Metal Powder Industries Feder- press technology in powder metallurgy with SMS Meer is a leading international company metal parts and assemblies. The PM its innumerable innovations from the very be- in heavy machinery and plant engineering. industry has grown along with the ginning. The perhaps most important in-house automakers to become a partner with development in recent years is the patented OEMs, meeting the product challenges “Controlled Punch Adapter Technology“ (CPA). of the marketplace as automakers It comprises seven precisely balanced steps continually create new cars and that guarantee optimum product quality – and trucks to satisfy consumer demand, adhere to government regulations and hence save ﬁ nishing, time and costs. www.sms-meer.com manage the changing complexity of a globalising marketplace. From iron bearings, transmission clutch plates, suspension ball joints and engine oil pump gears weighing just a few ounces, the PM industry has developed the technology to produce highly complex, special alloyed parts such a powder forged connecting rods, multilevel transmission carrier frames and engine VVT components (Figs. 1 & Fig. 1 Components such as this carrier and one-way rocker clutch assembly made for 2) while continually improving the price Ford Motor Company by GKN Sinter Metals, USA, have helped grow the PM industry and performance of “mature” parts to (Courtesy MPIF)

HPM 1200 E3 powder press Adapter changing system CPA 1200

Exhaust Gas Oxygen (HEGO) sensor North American auto production / Auto PM consumption Advantages of the PM components. PF connecting rods Process which typically weigh about 0.45 kg (1 lb) each increased consumption by • Eliminates or minimises machining the end of the decade to over 30,000 by producing parts at, or close to, short tons per year. Main bearing caps final dimensions weighing over 1.13 kg (2.5 lb) added • Eliminates or minimises scrap about 1.8–4.5 kg (4-10 lb) per engine losses by typically using more than on about 20% of the engines built by 97% of the starting raw material in the end of the decade. To improve the the finished part electronic engine controls, the use • Permits a wide variety of alloy of PM engine sensor rings increased systems dramatically because they provided cost effective parts yielding complex • Facilitates manufacture of complex or unique shapes which would designs and providing electronic Fig. 3 PM consumption in North America closely tracks auto production (Auto data be impractical or impossible with pulse reliability. Although the weight courtesy WardAuto/AutomotiveCompass) other metalworking processes of PM valve guides and seat inserts was not significant individually, the • Is suited to high-volume North American auto production / Weight of PM per vehicle component production Fig. 2 Powder Forged connecting rods continue to offer growth opportunities for the PM total volume demand per engine and requirements industry. This fracture split con-rod is manufactured by Metaldyne, USA, who manufac- the ability to fine tune the material ture more than 50 million connecting rods per year at various locations throughout the composition made PM a great design • Is cost effective world (Courtesy MPIF) selection.

Automatic transmissions ation (MPIF), North America’s PM cycle consisted of two levels - selling ment for materials and equipment, as The automatic transmissions trade association, recently reported the PM technology and then selling well as process improvements to help designed and produced in North that the PM parts content in the the part. Even with PM’s success in meet demand and the introduction America expanded the use of PM on a typical US-made car can be as high providing cost effective metalworking of new technologies. This in turn led numerous critical parts as transmis- as 1,000 individual parts representing solutions, with each new generation to the formation of many new PM sion torque converter hubs, transmis- 325 applications, with total weight of design engineer the selling of the companies, and a significant expansion parking hubs, sprockets, variable increasing slightly to 20.18 kg (44.5 lb) technology continues because of its sion of existing companies, throughout vane pump stators, rotors, body and this year. This compares with 19.95 kg limited academic exposure compared the 1990s. face plates. On a typical automatic (44 lb) in 2012, which itself increased to other processes. Another way to look at PM’s value transmission these components Fig. 4 Weight per vehicle has increased over the last 30 years and was estimated at in the automotive marketplace is the could add 2.75–8.15 kg (6-18 lb) per around 20 kg (44 lb) in 2012 (Auto data courtesy WardAuto/AutomotiveCompass) weight per vehicle benchmark (Fig. 4). transmission. Most of these compo- “The success of PM in the Over the last 30 years, PM content nents were converted to PM because automotive technologies being intro- per vehicle has grown from ~7.25 kg of improvements in material systems, Then the recession of automotive industry is driven by duced to meeting customer demand, (~16 lb) per vehicle to ~20 kg (~44 lb) part fabrication techniques and equip- 2008-2009 and its impact maximising automobile production estimated in 2012, an impressive ment advances, providing net or near the inherent advantages provided capacity and the automakers propping The impact of the 2008 recession and 275% increase since 1980. There was net shaped parts requiring minimal up sales with significant discounting the collapse of the auto market in 2009 by the PM process over other a significant PM growth spurt in the secondary machining. 1990s with PM per vehicle in 1990 and implementing severe supplier dramatically changed how the automo- metalworking technologies” at about 10.8 kg (24 lb) per vehicle cost reduction strategies which tive industry now views the marketplace PM in 4WD systems climbing to ~19.05 kg (~42 lb) in 2002, de-emphasised new product and and the way they conduct their busi- A third application system which PM a 175% increase. This per vehicle process developments. ness. Many changes taking place in the usage significantly benefited was four 0.90 kg (2 lb) from the previous year. In Automotive PM’s growth in increase, and the overall powder There were, however, a number automotive industry are having a direct wheel drive (4WD) transfer cases. The contrast, the PM content in the typical the 1990s consumption increase, was due to of PM part innovations that grew impact on the PM industry supporting 4WD volumes increased in the 1990s over the 2000s which included the the automakers, some of which are European-built car remained even last As reported by the MPIF, the region’s a number of factors: the growth in as the sales of pickup trucks and SUVs significant application of PM hydraulic being felt today while others are yet to year at 8.79 kg (19.4 lb), while the PM PM industry is heavily weighted to auto production; a shift from lower increased dramatically over conven- Variable Valve Timing (VVT) rotors, be determined. One major impact is content in the typical Japanese car the automotive market, with about PM content cars to much higher PM tional cars. These 4WD transfers cases stators and housings in engines; the the current strong rebound of vehicle declined slightly to 9.07 kg (20 lb). 73% of the structural PM components content trucks and SUVs; and the incorporated 3.6–6.35 kg (8-14 lb) proliferation of automatic transmis- production volumes and the strong The success of PM in the automo- produced being incorporated into significant expansion of new PM part of PM per assembly. The primary sion planetary carrier frames; and forecast for the future, and the ability tive industry is driven by the inherent North American cars and trucks. applications. applications included sprockets, hubs, automatic transmission mechanical of many suppliers without adequate advantages provided by the PM PM consumption in North America gears, oil pump rotors, planetary one way clutch components mostly capacity to meet this increase in process over other metalworking closely tracks auto production (Fig. 3). A new era in PM engine applications carrier frames and synchroniser rings. used in six speed transmissions. demand. This is due to some companies technologies. The automakers and This strong relationship created an PM applications grew dramatically These new products offset the lost PM downsizing and now being reluctant to suppliers needed a low cost, reliable environment in which to develop new supporting the rise in automotive The stabalisation of growth consumption due to design changes add capacity, while others are intro- metalworking technology that could materials, new processes, new equip- PM consumption during the 1990s. In the 2000s PM consumption and of various PM parts on some engines ducing new products and require new make millions of parts with little part ment technologies and develop new They included Powder Forged (PF) weight per vehicle consumption stabi- and the increase of foreign automaker capital for these products. This situation to part variation. PM has proven itself part applications that has provided connecting rods, crankshaft main lised in the 18–20 kg (40-44 lb) range market share gains in which these has created a new approach to how over decades by meeting these basic an opportunity to obtain a reasonable bearing caps, engine valve guides and as auto industry production peaked to automakers used considerably less products are introduced, priced, and criteria in which both the buyers and return on investments for these R&D seats in aluminium heads, engine 17 million unit levels. The emphasis PM content compared to the domestic how supplier/customer relationships sellers of PM parts have benefited. efforts. The increasing demand led to timing sensor rings, and engine stain- shifted from mainstreaming new automakers. are being defined. For many years, the PM selling significant growth in capacity invest- less steel exhaust flanges and Hot

in European and Asian engineering Diesel and alternative power systems North American engine production: design centre location centres. North American engine Alternative power systems such as North American engine production: Fuel type design will focus on V6 and V8 engines. hybrid and diesel engine are not With about 45% of the current engine meeting the volumes as numerous production in North America being trade reports originally suggested but designed in North America, it is will satisfy niche consumer markets estimated that this will shrink to (Fig. 7). These hybrid and diesel engine ~35% by 2020 as the four cylinder types use significantly less PM content engine market grows and the V6 and than typical North American gasoline V8 engine market share continues engines. Based on various trade fore- to shrink (Fig. 6). This reduction in casts, most of these alternative power the number of engine cylinders will systems are expected to be imported have a negative impact on future unless there is a significant consumer PM consumption. Such a shift will increase to these technologies. require fewer PM components and will demand new and more challenging Uncertain future trends design requirements of the existing parts and new parts being designed. in PM automotive Fig. 5 The location of the design centres responsible for designing the engines that are On the positive side, more foreign transmission applications manufactured in North America is predicted to change (Auto data courtesy WardAuto/ auto manufacturers are significantly Fig. 7 Gasoline engines are still expected to dominate the North American market North American transmission design AutomotiveCompass) expanding engine production in North (Auto data courtesy WardAuto/AutomotiveCompass) trends are going to have a major impact America to support domestic produc- on PM applications, just as engines North American engine production: Cylinders tion and some of these engines are are changing with new design and North American transmission production targeted for export. This increased production strategies (Fig. 8). Over the engine production will provide local last five years, there was shift from 4 sourcing of many PM parts for and 5 speed automatic transmissions companies positioned with design to 6 speed transmissions and the next and development resources overseas five years will shift again to 8, 9 and 10 to support the production demands speed automatic transmissions (AT), created in the North American market. Continuously Variable Transmissions (CVT) and dual clutch transmissions Gasoline engines (DCT). The older 4 speed transmis- North American gasoline engine sions contain 3.5–10 kg (8-22 lb) of PM production trends forecast a shift to content, the domestic automakers 6 fewer engine cylinders, VVT tech- speed transmission manufacturers nologies, direct fuel injection, turbo contain up to 16.5 kg (36 lb) of PM charging or supercharging, start/ content but some preliminary reports stop systems and a shift to electrical suggest the PM content of the new 8, 9 accessory systems such as power Fig. 6 Four cylinder engine production is predicted to rise in North America (Auto data and 10 speed automatic transmission steering, water pumps and oil pumps. courtesy WardAuto/AutomotiveCompass) may contain considerably less, but Ford, GM and Chrysler are expanding this is not confirmed. CVTs are gaining Fig. 8 Transmission design will have a major impact on PM applications (Auto data the use of many of these technologies New powertrain trends production momentum on smaller courtesy WardAuto/AutomotiveCompass) Another change in the auto industry to meet 2016 US CAFE Standards cars and are replacing conventional is the new fuel economy standards The powertrains being developed by and will require the automakers to automatic transmissions. Typical being implement by the US. These new the automakers are changing the reduce engine weight and significantly PM content is usually in the range of requirements are changing everything PM supplier landscape and they are increase engine performance with a 1.8-4.5 kg (4-10 lb), significantly less about the vehicle: the vehicle size and doing it on a global basis with shorter smaller engine package. This “power than conventional automatic transmis- material options; powertrain design and design cycle changes. Even though density” shift adds significantly more sions. European designed DCTs contain the globalisation of design and produc- most of the engines and transmis- stress and demands on many of the more PM content than CVTs but usually tion. Then add the equalisation of sions are being produced for use in current PM components such as contain less than domestically designed product quality of the automakers; the North America, more of the design connecting rods, sprockets, valve automatic transmissions. PM content changing demands and demographics and development work is being done guides and inserts and other related for DCTs is estimated to be in the range of the consumer and a number of other overseas in European and Asian components. These changes will of 2.75-8.25 kg (6-18 lb). cultural changes. This has created technical centres which historically require better material properties, PM content success in the auto- a need to redefine the automotive limited the application of PM technolo- improved dimensional accuracy and matic six speed transmission was due business model which will require gies compared to the current North more challenging durability cycles to a combination factors. GM and Ford continued business adjustments as the American design centres (Fig. 5). while still meeting commercial issues co-developed their six speeds and have marketplace evolves. The good news Based on reports by IHS Automo- of the automakers and PM parts had success with PM in their earlier with all this change in the automotive tive, future North American engines suppliers. In addition, many of these transmission versions; PM technology industry is that it creates significant will shift to smaller more powerful new engine systems will use PM has advanced significantly providing opportunities for those that are flexible units. Most four cylinder engines that components which should offset most cost effective design solutions for a Fig. 9 This automatic 8-speed transmission from ZF is based on a completely new and responsive to meet these new will be produced in North America of the losses incurred with the engine number of new design features used transmission concept. Such developments could offer significant new application demands with new products. have or will have their design roots downsizing forecasted. in the new six speeds; and many of opportunities for PM components (Image courtesy ZF Friedrichshafen AG)

the early designs were defined using to expand operations to support the served as an strong partners to PM driven by numerous end user North American automotive recovery advocate PM technologies within focused PM education programs. Key over the last three years. the domestic “Big 3” and created components used in many of the new This new North American automo- collaborative relationships from which transmissions are oil pump compo- tive business model is shifting from both the automakers and PM industry nents, carrier frame assemblies, one making parts at any price to selectively benefited by supplying and using cost way clutch components and other targeting part family applications effective metal components. Developing parts. with significant business potential a new generation of “PM Champions” yielding predetermined financial would not only serve to help develop

Future automotive PM results. This strategy is bringing to traditional uniaxially compacted parts market large, more complex parts but would also aid in the use of MIM trends using more specialised materials, parts and other PM technologies. Although the short term PM busi- more complex processes and more Finally, to increase the use of PM ness outlook is strong, the long term control of secondary operations by not only in North America and the rest automotive outlook for North America the parts makers. This technology of the world, the regional PM trade appears rather uncertain. Over the shift creates new opportunities for associations should consider collabo- last 40 years the PM industry has been companies that have global sales and rating more aggressively in the globali- driven by an entrepreneurial spirit product development networks to sation of the automotive technologies in which was supported by numerous design PM parts wherever any new order to support the global automotive part application opportunities; a engine and transmission designs are automakers and their key suppliers. relatively low cost of entry in the parts being developed and to produce them This collaboration could begin with a making arena and continuing material in their North American facilities. global market evaluation of various PM and process innovations. Those North American focused technologies in the automotive market, focusing on the similarities and differences as they relate to each region and “...the current trends suggest even country. The process could identify high with major vehicle downsizing and benefit opportunities for major global PM companies and regionally focused powertrain design changes, PM companies with the goal of increasing PM content for all member companies. - International Guest Speakers content should remain in the range in Finally, many believe that the automotive conventional PM market is in announced. the 17-19 kg per vehicle” decline, particularly in North America. If the industry continues on its current path, this “doomsday trend” is possible. Many of the existing applica- companies that try to convert wrought But to survive and prosper, rational tions have become “commoditised” type parts developed overseas (which change is needed to adjust for the - Registrations are filling fast! with many of the same parts being typically do not use PM components as changing global automotive industry re-sourced to different companies illustrated in PM content in European and to proactively create a logical plan driven by lower prices and usually and Asian vehicles) will have limited driven by good market research and an lower profit margins to the point success and the conversion success honest understanding of existing and that many of these applications that does occur will more than likely new business opportunities. Except for - Programme soon to be finalised. provided very small profit margins be the result of discounted prices. a handful of powertrain applications, but offered capacity utilisation of How successful this global develop- most automotive PM parts have market Go to www.tida.co.nz for more existing equipment and marginal cash ment strategy evolves will determine shares well under 50%, usually in the flows, particularly in the mid-size the direction of future automotive range of 30%. If there was an emphasis press range for those companies PM content in North America. In the on converting more developed parts details. with the lowest price. These low meantime, the current trends suggest to PM this new business could offer ROI parts limited reinvestment for even with major vehicle downsizing continued growth in North America. many smaller PM fabricators. But and powertrain design changes, PM larger companies owned by holding content should remain in the range Author companies or financially stable in the 17-19 kg (37-42 lb) per vehicle global parent companies were able to range through the rest of the decade. Eric Boreczky reinvest in new part applications and Another way to increase the rate Detroit, USA support this business by providing of PM consumption in the North Tel: +1 248 890 3735 the capital to grow the market. The American automotive market beside Email: [email protected] financial stress of this situation was the current activities is to reactivate significantly compounded by the efforts to develop “PM Champions” Eric Boreczky is an independent advisor recent North American recession. The to promote PM technologies within to the North American automotive good news was the strong automotive the auto companies and the major PM industry and has promoted PM recovery benefited those companies Tier 1 suppliers. Besides the market technology in the North American with significant new business devel- conditions of 1990s which nurtured the automotive industry in various roles oped efforts prior to and during the increases of automotive PM content since 1980. recession and the financial support per vehicle, these “PM Champions”

38 Powder Metallurgy Review Autumn / Fall 2013 © 2013 Inovar Communications Ltd © 2013 Inovar Communications Ltd Autumn / Fall 2013 Powder Metallurgy Review 39 MIM2014_A4 ad_Layout 1 8/20/2013 8:56 AM Page 1

International Conference on Injection Molding of Metals, Ceramics and Carbides Plansee Seminar 2013: FEBRUARY 24–26 • HYATT REGENCY LONG BEACH 4 LONG BEACH, CA The global refractory metals and hard materials industry meets in Make plans to attend Austria the only international metal and powder The 18th Plansee Seminar organised by the Plansee Group was held in Reutte, Austria, from the June 3-7 2013 and attracted more than injection molding Hyatt Regency Long Beach 500 international participants specialising in refractory metals and hard materials. In this exclusive report for Powder Metallurgy Review, Dr Leo Prakash reports on presentations highlighting global R&D event of the year! trends and the phenomena of cobalt capping.

MIM2014 CONFERENCE (February 24–26) A two-day event featuring presentations and a keynote luncheon • Advances in Component Uniformity • Part Selection—Best Practices The first Plansee Seminar, focusing on Global R&D trends in the rial and presented work carried out in • Leading Process Trends the science and technology of refrac- PM hardmetals industry recent years on fine grained mate- tory metals and hard materials, was rial, interfaces, alternative binders, • Numerous Case Studies organised by Prof Paul Schwarzkopf in Prof Dr Susanne Norgren and alternative sintering techniques, • Tabletop Exhibition & Networking Reception with 1952. The event has steadily grown in co- authors J Garcia, A Blomqvist gradient structures, high resolution Representatives from Many of the Leading both size and prestige to become the and L Yin, from the Sandvik Group, microscopy and electron back scatter premier global event for this important diffraction. They noted that among Companies in the Field in their comprehensive review paper, industry. confirmed that cemented carbide is emerging trends, coupling between ...and Much More! This year’s seminar boasted 123 still the undisputed leading cutting experiments and modelling at different accepted contributions in the field of tool, wear part and rock drilling mate- length scales has been growing, as refractory metals and 144 in the field of hard materials. The 109 oral pres- Optional One-Day Powder Injection Molding entations, special interest seminars and poster sessions drew large crowds Tutorial Precedes Conference (February 24) at all times. Starting with global overviews of Taught by Randall M. German, FAPMI This conference is sponsored by the the PM markets and R&D trends, world-renowned PIM expert the presentations addressed nearly Metal Injection Molding Association, all disciplines in this industry, from An ideal way to acquire a solid grounding in powder a trade association of the injection molding technology in a short period of time innovations in powder production Metal Powder Industries Federation to processing, materials and their • Introduction to the manufacturing process applications, from modelling and • Definition of what is a viable PIM or MIM component characterisation, and the important • Materials selection and expectations topic of recycling. • Review of the economic advantages of the process Our series of reports begins with a summary of a keynote paper presented during the opening session of the seminar focussing on global Visit mimaweb.org or mpif.org for complete program details and registration information research and development trends in the hardmetals industry. Fig. 1 Delegates during the opening session of the Plansee Seminar (Courtesy Plansee)

well as three dimensional modelling of both hardmetal producers and users, length scales is now a basic part of microstructure evolution. explained Norgren. product and grade development in As an introduction, some market The authors estimate that submi- the drive to create better products. data based on the ITIA 2011 Statistical cron grained grades now make up Atomistic and thermodynamic Overview of Supply and Demand [1] almost 50% of the world tungsten modelling mutually contribute to was presented by Norgren. “The total carbide market and anticipate that the understanding of interfaces and global tungsten market demand was this trend will continue to increase, interface structures. This is very 79,600 tons and if recycling was also not only due to a strong trend for relevant for submicron grades where included the actual consumption miniaturisation, for example, smaller the properties to a large extent are would have reached 103,500 - 111,500 computers, phones etc., but also due governed by the interfaces. tons. Out of this, 47,500 tons was to new and better Physical Vapour consumed by the hardmetal industries, Deposition (PVD) techniques which R&D trends not including recycling [Table 1]. If a have widened the use of PVD coated Selected topics discussed in this 30-40% use of recycled material is metal cutting inserts and rotary review are thermodynamic and kinetic Fig. 3 (a) Atomic resolution STEM image of a WC-Co interface showing a thin CrC(1-x) Fig. 4 Gradient sintered hardmetal. assumed the total tungsten consump- tools. On the other hand, rising metal modelling, submicron cemented layer in a WC -10 wt%Co -1.0 wt% Cr grade. (b) Extracted intensity profile from STEM- Typical steel turning grade in the P25 tion for hardmetals would have been consumption and associated mining carbide (focussing on the interfaces EELS line scan across the interface as marked in (a) (Courtesy Martina Lattemann, regime [4] (Courtesy Plansee) around 61,750 - 66,500 tons, of which activities have maintained a buoyant and inhibitor interfacial layers), alter- Sandvik Coromant) [4] approximately 45-50% would have demand for hardmetal rock drilling native binders, gradients, solubilities grain orientation. Calculations show and dust in the cemented carbide gradients, produced by denitridation of been submicron tungsten carbide.” tools, which are mainly coarse grained in WC and modelling in manufacturing that thin films inhibit grain growth industry production lines has been TiN-containing cemented carbides in Not only is tungsten consumption in microstructure. Furthermore, the processes and product applications. by the nucleation and growth of new studied by different organisations vacuum atmospheres, or γ-phase-rich in China continuing to grow faster production of cemented carbides for interlayers, not by inhibiting diffusion and the results could be a cause for surface layers produced by nitridation than in rest of world and is now 47,000 metal cutting remains an important Thermodynamic and kinetic modelling through the liquid binder. It comes concern. The alternative to cobalt as of cubic carbide containing cemented tons/year, some 59% of the world segment of the industry with incre- The several examples given in the as no surprise that the creation of an a binder is either iron based or nickel carbides. consumption, but this is accompanied mental improvements in the fifty area of thermodynamic and kinetic interlayer reduces the energy of the based. From the health and safety Special interest has been devoted by widened research and development year old CVD coating technology. In modelling clearly promote our system. An example of a measured aspect, nickel based alloys do not to the effect of alternative binders activity as well. Due to the higher this area, improving coating texture understanding of the fundamentals interlayer of CrC is shown in Fig. 3. offer any advantages, though they do (Fe-Ni-Co compositions) on the prices for tungsten raw materials, new and modelling of substrate surface behind how cemented carbides (1-x) exhibit a good combination of proper- formation of gradients and their mines outside of China are expected to gradient formation are hot topics of achieve their properties whether in Solubilities in WC ties, if tailored to the application. properties using nitrogen not only in be opened and the pressure to recycle interest. bulk or as gradients. Firm predictions Solubilities in and doping of the WC A vast body of past and current the WC-TiC_TaC system but also in the tungsten will continue to grow for Modelling at different dimensional of not only stability regions, melting crystal has found renewed interest literature on the pros and cons of Ti-Zr carbonitride system. Iron in the ranges, carbon balances, recipes and and it can be concluded that ab initio using iron as an alternative binder binder is beneficial for the formation other properties are available from the calculations are in sync with experi- exists and shows that replacing cobalt of gradients, due to the higher activity Thermo-Calc database software for mentally measured values. by application tailored iron based of nitrogen in iron. The effect is highly phase diagrams for many hardmetal It was already known that molyb- grades is possible, but also that more dependent on composition and process systems. However, thermodynamic denum is the only metallic element research work on alloy design and conditions. databases are never better than the that has a known solubility in the quality control issues are necessary. Computational thermodynamics has experimental data on which they are WC lattice, current research shows been successfully applied to model the based and here it is appropriate to that other than Cr with a maximum Gradients kinetics of gradient formation in both emphasise that some fundamental solubility of 5 wt%, all other studied Gradient cemented carbides allow Co-based cemented carbides. Good questions still remain unanswered elements like V,Ti, Mn, Ta. Nb, Co, Hf, tailoring important properties such agreement between experiment and even in the ternary W-C-Co phase etc. exhibited very limited solubilities as stiffness and toughness in a single simulation regarding layer thickness, diagram and we still have some way to in hexagonal WC in the range of 10-3 to hardmetal component in different phase fraction distribution and element go in spite of the diffusion models and 10-5. (W,Al)-C-Co composite cemented areas such as skin and core. Estab- profiles was obtained on DICTRA ab initio calculations. carbides are also of interest and it is lished gradients in the cemented modelling of gradient formation reported that the content x of Al in the carbide industry are the so-called kinetics considering that all diffusion Interfaces (W Al )C phase could vary between 0.2 γ-phase-free gradients for metal occurred in the liquid binder phase of a The importance of interfaces is 1-x x and 0.6. cutting applications and macro- dispersed system model for example in known and special attention on their gradients for rock tools applications . Ni-based cemented carbides. characterisation has found accept- REACH and alternative binders However R&D publications on develop- Nitridation of cemented carbides ance, especially in the field of fine REACH, so far, has classified cobalt as ment of γ-phase-free gradients in and cermets has once again been Fig. 2 There were a number of poster sessions to accompany the oral presentations grained hardmetals. Examples of very toxic for human health [2]. Also, cemented carbides have become fewer resurrected by various research during the Plansee Seminar (Courtesy Plansee) how Atom Probe Tomography (APT), the US National Toxicology Program, over the last decade. A reasonable schools in order to generate gradients High Resolution Transition Electron NTP [3], states that the tungsten explanation is the increased focus on that show superior wear properties in Europe Japan USA China Russia Microscopy (HRTEM) as well as ther- carbide-cobalt hardmetal dust has the development of novel CVD and PVD metal machining. modynamics and ab initio calculations Hardmetals 72% 75 % 66% 54 % 70 % been shown to be more toxic in coatings for machining applications, In the field of macro gradients, have helped to gain understanding combination than either pure cobalt or especially relating to coating composi- the Dual Property (DP) hardmetals Steels/Superalloys 9% 12 % 9% 28 % 14 % on how the interfaces are structured tungsten carbide alone. tion, nanostructure, adjustment of for mining applications are one of the and affected by inhibitors have been Mill Products/Lighting 8% 6 % 20% 11 % 16 % There has been a flurry of activity texture, residual stress, post treatment most well known cemented carbides published in the last ten years. to find alternatives to the cobalt processes and bonding between layers since 1988 using macro-gradients. Chemicals and Other 11% 7 % 5% 7 % 0 % It can be safely incurred that thin binder in hardmetals, not only since and layer to substrates and more. Controlled redistribution of the cobalt films are present between the WC the spectre of REACH has become Current research mainly focuses binder phase gives components which Table I ITIA 2011 Statistical Overview of Supply and Demand, the percentage of the W grain boundaries, their occurrence reality. The potential health risk of on the production, characterisation contain three distinct microstructural used by different market areas [4] (Courtesy Plansee) depending on the composition and inhalation of hardmetal raw powders and modelling of either γ-phase-free zones. These gradients, together with

FEM can effectively assess stress universality of application and produc- surface and others didn’t. Cobalt capping is very rapid and occurs in a distribution under different pressure, tion friendliness in a highly competitive capping leads to a layer of binder on narrow temperature range, normally as well as changing dimensions market. Nevertheless, alternative the sintered surface and should not be starting from the top of the sample and shape of the designed carbide binders are a future trend and will be confused with Co-enrichment, which and moving downwards by a nucleation component. Engineers also utilise even more important due to the new causes surface near gradients of Co in and coalescence mechanism. FEM to simulate chip formation in the health legislations for Cobalt.” the product. The authors explain the cobalt machining process, residual stress Norgren stated that “Modelling of Three papers [5- 7] at the 18th layer formation during cooling as a in micro-milling, wear mechanisms manufacturing processes and product Plansee Seminar dealt with the result of two interacting mechanisms. and the influence of cutting heat on applications, will play an even more phenomena of the evolution and In between the solidification interval tool life and to understand the plastic important role in carbide industry. It possible mechanisms of cobalt during cooling, binder phase can deformation and fracture of hardmetal, will cover a wide range of applications, capping. be transported either towards the also under fatigue conditions. The from materials grade development, surface (decarburising conditions) development of measurement and process optimisation, design auto- Understanding cobalt layer forma- or towards the interior of the sample experimental techniques is very mation, to product application and tion: In situ observation and new (carburising conditions). This is much concurrent with modelling performance. Concluding the work insights on the mechanism caused by different amounts of liquid improvement. being reviewed here, the future trends The research work presented by E binder as a result of the varying are: 1) Moving towards hierarchical Sachet and his colleagues [5] was carbon content due to reactions Conclusion & outlook modelling or multi-scales modelling fascinating, as for the first time it with the sintering atmosphere or by In her closing remarks, Norgren at different scale, micro, meso, and showed a real time experimental temperature gradients inside the Fig. 5 The three distinct zones of the DP- carbide (Courtesy of T Hartzell, Sandvik stated, “A clear focus area for macro, 2) Full product modelling documentation of the appearance of sample. After an initial transport of Mining Rock Tools) [4] metal cutting and wear parts is from product design to processing cobalt on the surface of hardmetal binder phase towards the surface, the fine grained hardmetals. In metal and application, 3) Model validation, samples during cooling. These authors layer formation is then driven by the cutting, improved PVD techniques including materials characterization studied primarily the influence of the surface tension of the cobalt and the generating thin coatings on sharp and measurement, and 4) Product cooling rate in the temperature range layer forms as a result of optimisation cutting edges which benefit from performance monitoring.” between 1360 to 1300°C for different of the surface/volume fraction of the fine grained cemented carbides, alloys with different grain sizes (0.6 – 4 binder on the surface. widens the application field for inserts Mechanisms of cobalt microns), grain growth inhibitors (Cr The morphology of partially formed and round tools. In solid endmills and Ta) and different surface carbon cobalt layers strongly support this and drills, PVD coated fine grained capping contents. mechanism as the different steps cemented carbides are taking market The influence of carbon content on the The sequence shown in Fig. 7 observed agree with the proposed share from traditional high speed bulk properties of Hardmetals is well represents five steps, from a complete model and confirm the strong influ- steel cutting operations. With the known. However it is the surface of cobalt-free surface to a continuous ence of the cobalt’s surface tension. increasing knowledge about interface the hardmetal that plays an important cobalt layer, and demonstrates the In situ observations provided structures, doping and properties this characteristic morphologies of the additional data that support the Fig. 6 Examples of FEM simulations for Sandvik products (a) Stress distribution in a role in determining the usability of area will continue to grow. Combined cobalt layer formation observed for the formulated mechanism and add stainless steel wire drawn through a hardmetal die (b) Image of the calculated stress hardmetals. The emergence of near with the increased research activity materials used in this work. extra insight into the time scale and distribution within a press-fitted hardmetal tool [4] (Courtesy Plansee) net shape hardmetals which undergo in alternative sintering processes none, or a minimum amount, of The authors could clearly show progress of the formation. Cobalt their differences in thermal expansion, of hardmetal since it is a composite such as, for example, field assisted grinding before being pressed into use that, depending on alloy composition, layer formation is indeed a fast redistribute the internal stresses. It is, consisting of metallic binder and hard sintering, spark plasma sintering and has resurrected the interest on the slow cooling promotes cobalt capping process that happens within a time for example, possible to create a very refractory metal phases. pulsed electric current sintering, the morphology of the as-sintered surface and it is easier to form a cobalt layer frame of 30-120 seconds and starts hard and wear-resistant surface layer Continuing development of model- opportunity to go even finer in grain of hardmetals. for alloys with a smaller grain size at numerous points on the sample which is simultaneously pre-loaded ling methods is needed to simulate size on an industrial scale will be Until about perhaps a decade ago, or a higher cobalt content under the surfaces. The duration and the with compressive stresses to prevent hardmetal pressing and sintering possible. Increased understanding of the sintered skin of hardmetal had vacuum sintering conditions used starting temperature of the formation the initiation and propagation of processes. One recent attempt is a the physical phenomena governing WC to be removed before use, since the in this study. The process of cobalt are dependent on the solidification cracks. Carbide having such a distri- multi-scaled or hierarchical model, grain growth and interfacial properties as-sintered surface was neither well bution of properties has high wear which tries to integrate different gained from combined atomistic and defined nor defect free. It was quite resistance at the surface combined dimensional orders of scale together. thermodynamic modelling together common to advise hardmetal product with a tough underlying region. The Intrinsic properties resulting from with microscopy studies will almost users to grind away about 0.2 mm initial application area was in rock pressing could be considered as input certainly result in further development of the surface to get full value for drilling but today macro gradients are to the modelling of sintering, such as of fine grain cemented carbides.” money. However, surface grinding is also used for tube and wire drawing initial inhomogeneity of microstruc- “In the future we will see an an expensive process and the first step tools and cold heading dies. ture, distribution of WC and pores, increased use of 3D techniques; to engineer the surface and reduce and localised residual stress in ‘green for example the 3D atom probe and grinding is to study the as-sintered Modelling in manufacturing process body’. Other factors such as grain reconstructions of real 3D structures surface morphology. and product application growth, phase change, heating cycle, by combining Field Ion Beam (FIB) and On the other hand, to improve Modelling has become a powerful should also ideally be included. EBSD techniques,” Norgren added. brazeability many mass produced tool in engineering and the hardmetal Modelling can shorten the new “High R&D activity in the field of hardmetal products have to be given industry is no exception. Modelling product development cycle, optimise alternative binders will continue. an additional thin electrolytic coat of carbide production processes and parameters for field applications, and Fe-based alternative binders are of metallic nickel or cobalt. It has applications are prevalent in the significantly reduce cost before going used in some applications such as been quite a riddle to hardmetal industry with reasonable success. But into mass production (Fig. 6). woodworking and special wear parts, manufacturers to see that some it is a challenge to develop suitable In the design of hardmetal anvils more effort in alloy design, production hardmetal parts had a skin of cobalt models to describe the behaviour for diamond synthesis for example, and quality control is required to attain (cobalt- capping) on the as-sintered Fig. 7 The different stages of cobalt layer formation [5] (Courtesy Plansee)

defect-free Co coatings, with dramatic the early stages of the cooling step, cermets show different cobalt capping improvements of their as-sintered indicating that the enrichment occurs characteristics (Fig. 12 and Fig. 13). TRS, surface fracture toughness and as soon as the surface is decarbur- Fig. 12 shows that sintering in an wettability by braze alloys. ised. This effect is even stronger for argon atmosphere during cooling The technology is based on a step- vacuum conditions; but as observed, has led to a perfect cobalt capping wise cooling of hardmetal products the actual Co-capping may be absent for all cermet compositions. Fig. after sintering in different temperature due to evaporisation of binder. Since 10 shows the surface of the same ranges at tailored rates. Fig. 10 shows the solidification temperatures and cermet types sintered under a high the cobalt film on a hardmetal cross intervals depend on the cermet carbon activity (CO pressure below 50 section and some products obtained composition, (Table 2) different mbar). It is quite clear that the carbon with a shiny surface by using the cobalt capping technology. As in the case of the previously Fig. 8 Examples of different surface morphologies of sintered WC-10% Cobalt Hardmetals with different mean WC grain sizes: a) mentioned paper by Sachet et al., Fine grained Hardmetal with a cobalt film on the surface, the content being 76 Wt.%; b) Medium grained Hardmetal with islands of the underlining mechanism of cobalt Cobalt films on the surface and a surface cobalt content of 18,7 Wt. %; c) Coarse grained Hardmetal with no surface cobalt film and capping is based on the knowledge a cobalt content of 14 Wt.% [6] (Courtesy Plansee) of the ternary WC- Co phase diagram interval of the alloy used and thus by (Fig. 11). the composition and WC grain size. This school of researchers Controlling cobalt capping in postulate that the mechanism cannot sintering process of cermets be used to create thick surface layers The third paper on the topic is from of cobalt, as the transport of sufficient S Englund and colleagues at Sandvik amounts of cobalt requires very slow [7] who studied cobalt capping of cooling rates and would lead to the cermets. In this work critical sintering disintegration of the tungsten carbide parameters for the formation of cobalt skeleton. Faster binder transport capping on four different cermet is also not possible because the grades were evaluated experimentally. hardmetal microstructure will eventu- The influence of the carbon activity, Fig. 9 Surface of fine grained WC-10% Co Hardmetal: a) fast cooling after sintering, ally be binder depleted and block the sintering atmosphere (vacuum, the surface is coated with a discontinuous Co film . b) slow cooling after sintering, the further transport towards the surface. flow rate, pressure, high pressure) and surface is coated by a continuous Co film [6] (Courtesy Plansee) To prevent the formation of a cobalt the cooling rate was investigated. layer, the process has to be either The results are in accordance prevented by fast cooling within the with the known observations that solidification interval, or by applying the Co surface top-layer forms Fig. 12 SEM images of the top surface for different cermet alloys using an inert argon mild carburising conditions upon during a specific short temperature atmosphere [7] (Courtesy Plansee) cooling and therefore inhibiting binder interval during the cooling step for transport towards the surface. each grade, but it is affected by the Sample WC Co Ni cc-phase* preceding conditions; e.g. enhanced Cobalt Capping: A technique for by a preceding Co-enrichment in CERMET 1 balance 11 5.5 67 improving the transverse rupture the surface zone in a decarburizing CERMET 2 balance 11 5.5 67 strength, fracture toughness and atmosphere. wettability by braze alloys of WC-Co The formation can be inhibited by CERMET 3 balance 14 - 67 hardmetals using a carburizing atmosphere, such CERMET 4 balance 18 - 67 Fig. 10 Co Films on hardmetal products obtained by the Co capping technology [6] The second paper on cobalt capping as carbon monoxide gas, or a sinter- (Courtesy Plansee) under industrial conditions for HIP (Hot Isostatic Pressure) step * cc-phase is a carbonitride containing the metals Ta, Nb, W, Ti different carbide grain sizes and during cooling. A phenomenological binder contents was presented by I model for formation of Co-capping Table 2 Chemical composition of the investigated cermets (Wt.%) [7] (Courtesy Plansee) Konyashin et al. [6] from Element 6. in cermets considering melting point His explanation of the mechanism of of alloys, cobalt migration, carbon DSC-TG CERMET 1 CERMET 2 CERMET 3 CERMET 4 cobalt capping is based on the action activities, vapor pressure of reactive of capillary phenomena in thin chan- elements as well as processing Melting begin 1367 ±1 1382 ±1 1406 ±1 1405 ±1 nels between WC grains on liquid Co in parameters (sintering atmosphere, Melting finish 1386 ±1 1411 ±1 1416 ±1 1416 ±1 the hardmetal near-surface layer. cooling rate etc.) was presented. The mechanism supposedly The experimental results on ΔT 19 ±1 18 ±1 10 ±1 19 ±1 explains all the phenomena of the Co Co-capping formation on cermet Solidification 1364 ±1 1396 ±1 1407 ±1 1411 ±1 layer formation during sintering of materials in this study are in general begin various hardmetal grades followed by agreement with the observations Solidification 1331 ±1 1373 ±1 1391 ±1 1387 ±1 either fast or slow cooling. The authors carried out for WC-Co hardmetal finish report that a new technology for the materials in the literature. EPMA ΔT 33 ±1 22 ±1 16 ±1 24 ±1 fabrication of Co coated hardmetal line-scans have shown a deeper articles has been developed on an depletion curve of cobalt when the Table 3 Melting and solidification temperatures of the investigated cermets [7] industrial scale for hardmetal articles CO (carburising gas) was removed at (Courtesy Plansee) Fig. 11 Ternary phase diagram Co-W-C at 10 Wt.% Co [6] (Courtesy Plansee) of different grades with continuous and

the type of trays and location of the samples in the batch also affect the Co-capping formation. Since all the processes are sensitive to the partial pressure of the system, the Co-transport may be inhibited by conditions New for 2013 that increase the CO partial pressure locally. This phenomenon could also explain why the bottom surfaces of Additive Manufacturing Sessions the samples often have much more surface Co than the other surfaces of the same samples when sintering at low pressures. EURO PM2013 References CONGRESS & EXHIBITION [1] ITIA Report, Tungsten Statistical Report, September 2012 [2] http://ec.europa.eu/environment/ 15 - 18 September 2013 chemicals/reach/reach_intro.htm [3] http://ntp-server.niehs.nih.gov/ Svenska Mässan, The Swedish Exhibition and Congress Centre, [4] E Sachet, G Mühlbauer, J Yukimua, Y Kubo, W D Schubert, Understanding Gothenburg, Sweden Cobalt Layer Formation: In Situ Observation and New Insights on the Mechanism, Proceedings 18th Plansee Fig. 13 SEM images of the top surface for all cermets sintered under a carburizing Seminar, Reutte, 2013 atmosphere (CO < 50 mbar) [7] (Courtesy Plansee) [5] E Sachet, G Mühlbauer, J Yukimua, activity has a significant impact on Co using a CO atmosphere during the Y Kubo, W D Schubert, Understanding capping. Other published literature cooling step avoiding Co-transport Cobalt Layer Formation: In Situ has also shown this relationship that towards the surface and the Observation and New Insights on the a change in carbon balance results in formation of the binder-layer. Mechanism, Proceedings 18th Plansee Seminar, Reutte, 2013 changes on the surface solidification • Both a CO atmosphere and a [6] I Konyashin, S Hlawatschek, B temperature and thus a non equilib- HIP-treatment during cooling Ries, F Lachmann, M Vukovic, Cobalt rium condition between liquid and avoid Co-capping formation. Capping: A Technique for Improving solid binder, leading to Co migration However, it can not be stated if the the Transverse Rupture Strength, towards the interior of the samples CO-cooling and the HIP-cooling Fracture Toughness and Wettability by under carburising conditions. have different underlying mecha- Braze Alloys of WC-Co Hardmetals, nisms. For example the question Proceedings 18th Plansee Seminar, Conclusions if the high pressure mechanically Reutte, 2013 Conclusions and recommendations pushes the binder phase towards [7] S Englund, F Haglöf, J García, to control Co-capping formation in the interior of the sample, or if the Controlling Cobalt Capping in Sintering cermet grades have been summarised HIP results in an increase of the Process of Cermets, Proceedings 18th by the authors as follows: CO partial pressure due to release Plansee Seminar, Reutte, 2013 • Based on these results, it can of impurities in the furnace still be concluded that the impact needs clarification. Regard- of cooling rate variations on less of the mechanism behind Acknowledgements An all topic powder metallurgy event focusing on: Co-capping formation in cermets Co-capping, the furnace pressure is less compared to the reported and atmosphere are critical. This review was prepared from the effects on WC-Co grades. Cooling • If Co-capping is achieved during Proceedings of the 18th Plansee • Structural Parts PM rates below 5°C/min have a lower the sintering, it is still necessary Seminar, Reutte, June 2013. impact on Co-capping forma- to avoid binder evaporisation. • Hard Materials and Diamond Tools tion and a considerable effect Co evaporisation is fast at low Author on the final particle size in the furnace pressures (vacuum condi- Dr Leo J Prakash holds a PhD in • Hot Isostatic Pressing microstructure. tions) and at high temperatures. Cemented Carbides and has over three • The Co-capping may occur The results show that cermets • New Materials and Applications decades of experience in the field of during a specific temperature grades with higher solidification cutting tools for wood and metals interval during solidification of the temperatures and longer solidifi- • Powder Injection Moulding as well as wear parts. Email: Leo. samples as reported in previous cation intervals are more sensitive [email protected] publications. to evaporation if they are sintered • NEW for 2013 Additive Manufacturing • Co-capping can be avoided by in high vacuum atmospheres. increasing the carbon activity in Finally the authors find it worth the surface of the cermets, i.e. by mentioning that the sintering furnace,

PowderMet 2013: State of the North American Powder Metallurgy industry

The PowderMet 2013 International Conference on Powder Metallurgy and Particulate Materials was held in Chicago, USA, from June 24-27. Organised by the Metal Powder Industries Federation (MPIF), the event attracted over 800 participants and included three days of presentations and a trade exhibition. A keynote presentation by MPIF President Matthew Bulger gave delegates a detailed overview of the current state of the North American Powder Metallurgy industry.

In his opening address at PowderMet last year by 4.7% to 16,209 short tons, 2013, MPIF President Matthew Bulger stated Bulger (Fig. 4). (NetShape Technologies, Inc.) stated Of the other materials, tungsten that most metal powder producers, and tungsten carbide powders regis- equipment makers and PM parts tered minor declines, while stainless companies, especially fabricators of steel, molybdenum, and nickel Metal Injection Moulded (MIM) parts, powders experienced modest gains. had reported increases in sales during Recent new information on aluminium 2012. The industry, he reported, had powder shows a substantially larger regained its growth momentum and market than previously reported at 2013 is expected to offer a repeat of some 80,000 short tons. last year’s modest but positive gains. According to MPIF statistics, the Bulger reported that total 2012 market for MIM powders grew 35.5% metal powder shipments increased in 2012 to 1,971,580 pounds (895 mt). by 9.6% to an estimated 507,643 short However, because these statistics tons (Fig. 2). Iron powder shipments in do not include all powder makers, 2012 rose 5.5% to 383,984 short tons, observers put the market higher at representing the third consecutive approximately 2-3 million pounds, year of steady growth. Of this total the added Bulger (Fig. 5). PM parts share grew by almost 6% to PM process equipment makers, Fig. 1 Matthew Bulger stated that most 343,777 short tons (Fig. 3). especially compacting press builders, metal powder producers, equipment North American shipments of highlighted an upward trend by part makers and PM parts companies had copper/copper-base and tin powders makers to increase their manufac- reported increases in sales during 2012 for PM applications actually declined turing capacity for PM parts. Press (Courtesy MPIF)

variable valve timing (VVT) systems will solar, and space applications. of the worldwide metals and materials North American metal powder shipments North American iron powder shipments continue to grow in order to help OEMs Addressing the topic of Additive fields, PM may be a blip on their radar meet 2016 CAFE standards,” he added. Manufacturing (AM), Bulger noted screens. But on the other hand, many It is estimated that the PM parts that laser-sintering 3-D printers show industries would grind to a sudden content in the typical US made car, can promise sintering metals for complex stop without our vital technology.” be as high as 1,000 individual parts aircraft parts. “PM was heralded as a twentieth representing 325 applications, and century technology based on superstar will increase slightly to 44.5 pounds A bright future products, and it will gain new status as (20.2 kg) this year. This compares a global technology in the twenty-first with 44 pounds (20 kg) in 2012, which “Investing in applied and fundamental century. That is, if we encourage that had increased two pounds from the research is vital to our industry’s insatiable curiosity to conceive new previous year. In contrast, the PM future,” stated Bulger. “Technology ideas, maintain the entrepreneurial content in the typical European built breakthroughs may take years before spirit of the pioneers who launched the Fig. 2 North American metal powder shipments 2009 - 2012 Fig. 3 North American iron powder shipments 2009 - 2012 car remained even last year at 19.4 true commercial applications, but we PM industry, and cooperate through (Copyright MPIF) (Copyright MPIF) pounds (8.8 kg), while the PM content must never neglect researching new joint development programs world- in the typical Japanese car declined ideas and funding them. In the context wide,” concluded Bulger. North American shipments of copper and copper North American MIM grade powder shipments slightly to 20 pounds (9.1 kg). Both base/tin powders countries experienced a decline in vehicle production, added Bulger. The PowderMet 2013 exhibition Powder Forged (PF) connecting rods remain one of PM’s stellar successes, dating back to its first use in North America in a Ford 1.9 litre engine. About 60% of North American auto engines use PF rods currently. Worldwide, it is estimated that more than 850 million PF rods have been Fig. 4 North American copper and copper base/tin powder Fig. 5 North American MIM grade powder shipments 2009 - 2012 produced since 1987, with no major shipments 2009 - 2012 (Copyright MPIF) (Copyright MPIF) failures reported.

sales registered very strong gains to 136,535 short tons. Copper-powder commented Bulger. Although casting Technology developments last year compared with 2011, and the producers are cautiously upbeat, densification dominates HIP usage, “Metal powder producers continue to industry ended 2012 with a backlog of stated Bulger, forecasting annualised representing about 70% of the market, invest in programmes to improve PM more than $19 million, reported the growth in the 3 - 6% range. PM applications are also growing for materials and expand PM parts appli- MPIF’s Powder Metallurgy Equipment Equipment makers anticipate MIM part densification, tool steels, and cations,” stated Bulger. “For example, Association. increased business levels based on oil- and gas-exploration projects. one company is developing a new high “PM parts makers serving the capacity expansions among PM parts Weakening demand characterises density lubricant binder that provides automotive market fared very well last fabricators, especially the addition of the tungsten market outlook along higher single pressed densities via year, while those serving the industrial presses in the 100 to 500 ton range. with softer raw materials prices. warm compaction. A competitor is market and products related to home Bulger reported that larger multi Both the carbide and tungsten alloy working on developing new lubricants building experienced more modest plant PM parts makers, especially shipments were down during the first with improved hygroscopy resistance growth,” added Bulger. auto-parts suppliers, are adding new quarter, particularly tungsten carbide and ejection. Another company has MIM companies recorded a solid capacity to meet growing demand. products in mining and construction a new line of stainless steels that year of increased sales in 2012. The Some medium and smaller size family industries. Defence applications are improves machinability two to three hot isostatic pressing (HIP) industry owned businesses, who supply the also down, heavily impacted by the times over standard stainless grades.” enjoyed another outstanding year as broader industrial marketplace, are government’s sequestration program. “Compacting press builders are well, based on casting densification signalling a mixed outlook. However, oil and gas drilling applica- designing enhanced high tonnage CNC and the processing of MIM parts to full The MIM industry continues to tions are doing well, and aerospace hydraulic presses and higher speed density. thrive with annual North American applications are on an upward trend. designs,” continued Bulger. “Several sales estimated at $250 -$300 million. firms are focused on supplying PM 2013 outlook for North Firearms applications remain the PM automotive trends parts for an innovative stationary fuel leading MIM parts market followed system that converts natural gas America “This year could see North American by medical/dental, general industrial to oxygen and hydrogen to produce light vehicle production rising well Turning to current conditions, Bulger products, automotive, and electronics. electric energy.” above 15 million units. However, said that even in the face of robust As far as the automotive market is Additionally, researchers are the really big increases should hit auto sales, a recovering US manu- concerned, there are applications studying powder based composites the market in 2015-16 when many facturing base, and a rebound in new where MIM technology is indispen- for defence and energy applications. new models with new engines and home construction, PM executives still sable, in components for electric and Potential uses include aluminium transmissions are introduced,” forecast only modest growth because hybrid vehicles and in new turbo- alloys for lighter-weight marine and stated Bulger. “This trend includes consumers remain wary about the US charged gasoline engines. armoured vehicles, iron based soft more four and six cylinder engines, economy. The Hot Isostatic Pressing (HIP) magnetic composites for motors, turbochargers, and six, seven, and Iron powder shipments through the outlook signals another good year that compressors, and power conversion, eight speed transmissions. The use of first four months have increased 6.7% should continue well into the future, and nanomaterials for nuclear energy,

PM industry Distinguished Service Awards professionals The MPIF also announced recipients of its Distinguished Service to Powder recognised at Metallurgy Award. Established in 1968, the award PowderMet recognises North American indi- viduals who have worked a minimum 2013 Fellows Dr Olle Grinder (left) and Roger Lawcock of 25 years in the PM industry and APMI International, a profes- receive the 2013 APMI Fellow Award whose long term contributions sional society for the PM industry, and achievements deserve special welcomed both Dr Olle Grinder, of the roll-densification process for recognition. This year’s recipients are: Consultant, PM Technology AB, and gears, converting numerous gears • Susan M Abkowitz, COO and Vice Roger Lawcock, Director, Product from wrought to PM. A member of President of Technology, Dynamet & Process Development, Stackpole APMI for nearly 20 years, Lawcock Technology, Inc. International, to the 2013 Class of has promoted the advancement of • Robert T Beimel, President, JIT Fellows. They received the award PM as a science by disseminating Tool & Die, Inc. at a special luncheon held during and exchanging information through • Russell A Chernenkoff, Senior PowderMet 2013. his many publication efforts. He Research & Development Dr Grinder is a world renowned received the MPIF Howard I Sanderow Engineer, Metaldyne LLC Outstanding Technical Paper Award powder metallurgist who has actively • Mark S Greenfield, Vice President, as the outstanding technical paper at contributed to the advancement of Global Material Science, Kennam- the 2005 annual conference, as well PM technology in Europe, Asia and etal Inc. North America. A member of APMI as the SAE Arch T Colwell Award for • Paul A Hauck, Director, Engi- for over 27 years and possessing significant contribution to literature. neering, Marketing & Sales, over 43 years of PM experience, Lawcock received his MSc in Kinetics Climax, Inc., Dr Grinder has published 60 reports metallurgy from the University of • Roger Lawcock, FAPMI, Director in international journals or confer- Manchester, UK, in 1987. In over 30 Product & Process Development, ence proceedings. years in PM, Lawcock has focused Stackpole International, Automo- Dr Grinder has made unparal- on high volume, high performance tive Gear Division leled contribution in fully dense automotive applications based on lean • Gilles L’Espérance, FAPMI, PM technology, and is one of the alloys, high temperature sintering and Professor, Materials Engineering, leading experts on the subject of Hot improvements to core and surface École Polytechnique de Montréal Isostatic Pressing (HIP). A recipient density. He has been instrumental of a PhD in metallurgy and material during the material and design • Michael E Lutheran, President, science from the Royal Institute of development phases of several award Royal Metal Powders Inc. Technology, Sweden, in 1977, he has winning components. • Nicholas T Mares, Vice President made significant contributions in the Established in 1998, the Fellow of Marketing, Asbury Graphite sintering of high alloys, including Award recognizes APMI members for Mills, Inc., tool steels, stainless steels, and their significant contributions to the • James J Oakes, Vice President, ATI cemented carbides. He is author/ society and high level of expertise Tungsten Materials, Metalworking co-author of four patents, two of in the technology of Powder Metal- Products which directly related to PM, and has lurgy, practice, or business of the PM • Richard Pfingstler, CEO, Atlas been a lecturer at the Royal Institute industry. Fellows are elected through Pressed Metals of Technology for over 25 years. their professional, technical and • Joseph T. Strauss, President, HJE Lawcock is one of the pioneers scientific achievements. Company, Inc.

Winners of the 2013 MPIF Distinguished Service Awards. Left to right: Joseph T Strauss, Richard Pfingstler, James J Oakes,Nicholas T Mares, Michael E Lutheran, Gilles L’Espérance, Susan M Abkowitz, Robert T Beimel, Russell A Chernenkoff, Mark S Greenfield, Paul A Hauck and Roger Lawcock (Courtesy MPIF)

PowderMet 2013: Continuing technical developments offer growth for the Powder Metallurgy industry

The Special Interest Program at PowderMet 2013, held in Chicago, June 24-27, 2013, proved to be an excellent opportunity to showcase the advances in Powder Metallurgy. In the session “Technologies for PM Growth” authors identified material and process developments that offer improved properties, allowing PM to compete against existing technologies and provide opportunities for growth. Dr David Whittaker reports exclusively for Powder C Metallurgy Review on a number of key presentations. M

CMY

From raw material to new The opening presentation in this reduced energy consumption and challenging applications session came from Ulf Engstrom, higher material utilisation in the (Höganäs AB, Sweden) on behalf of component forming process itself, The Special Interest Program on Tech- his co-authors, Caroline Larsson, are well documented. However, nologies for PM Growth began with a Sigurd Berg and Christophe Szabo. the comparisons provided at the series of presentations from the major It is recognised that green issues opening of this presentation were powder suppliers, highlighting the are becoming an increasingly considerably more rigorous than this material and process developments important factor in determining the in that they involved full life cycle that they had introduced with a view to relative merits of competing materials analyses, beginning with mining/ opening up new higher-performance and technologies. The benefits of extraction of raw materials and application opportunities for the PM, as compared with wrought ending with end-of-life recycling of ferrous PM structural parts sector. steel processing routes in terms of components.

Weight of final Material Material Processing component, g utilisation, % Steel technology Cut from bar, Forging, SS2225 194 68 Machining, Heat (25CrMo4) treatment PM technology Astaloy Compaction, Sinter 196 97 CrM+0.3C hardening D. Compaction, Sintering, 196 97 AE+0.5C Heat treatment

Fig. 1 The component selected for the life cycle analysis case study and the relevant material and processing data [1] (Courtesy MPIF)

These materials are well suited to Forged steel Powder Metallurgy processing by sinter-hardening and Fig. 5 shows that, on sinter-hardening with a carbon gradient, the Astaloy CrA + 2% Ni material can achieve fatigue and tensile strength levels comparable to much more highly alloyed heat treated materials and unique combinations of fatigue strength and elongation, even at room temperature compaction density levels.

Outlook The presentation concluded with some predictions as to how these material and process developments can enhance PM’s capability for attacking growth opportunities in challenging product Fig. 2 Life cycle analyses showing the superiority of PM over steel processing in terms of environmental impact [1] (Courtesy MPIF) applications. Fig. 6 provides some views as to how the highlighted materials might fit into a number of important Fig. 5 Fatigue and mechanical properties of sinter-hardened materials, based on existing and potential product niches, Astaloy-CrA or Astaloy CrM [1] (Courtesy MPIF) including the industry’s “holy grail” of transmission gears. Finally, the promise was discussed of future developments of “low pressure processing”, involving vacuum sintering and gas quenching, that might provide further enhancements in the properties of the highlighted Cr-alloyed grades and how these processes might be combined with state-of-the-art hard finishing operations to provide an optimised PM gear production route.

Fig. 3 Plane bend fatigue strengths of Distaloy AQ in Fig. 4 Comparison of pore sizes and probability of occurrence in Distaloy New lubricant system the through-hardened (left) and case-hardened (right) AQ products produced by warm compaction and room temperature facilitates higher density PM conditions [1] (Courtesy MPIF) compaction [1] (Courtesy MPIF) parts Francis Hanejko (Hoeganaes Corpora- Environmental impact factors Secondly, the comparisons of the Fig. 3 shows the levels of plane tion, USA) gave an update, on behalf These analyses considered the two PM material types showed the bend fatigue strength attainable in the of his co-author Shelton Clisby, on environmental impact factors: environmental credentials of using case-hardened and through-hardened the development of a new lubricant • Global Warming Potential (CO , 2 the chromium-containing Astaloy CrM conditions at room temperature system, which, in combination with Fig. 6 Challenging growth areas for PM and potential materials [1] (Courtesy MPIF) CH4) - GWP material as compared with the 4% Ni compaction and warm compaction • Photochemical Ozone Creation Distaloy AE. Although the move away density levels. The benefits of warm Potential - POCP from PM materials highly alloyed compaction in relation to fatigue with Ni is partially motivated by cost strength are related to the reduction in • Acidification Potential (SO , NO ) 2 x considerations, these green issues both the size and frequency of occur- - AP are also of increasing importance in rence of large pores in the sintered • Eutrophication Potential (NO , x material selection and Cr- and leaner structure (Fig. 4). PO ) - EP 4 Ni-alloyed grades offer the opportunity The highlighted Cr-alloyed mate- As a case study, production routes to fulfil these requirements, stated the rials were the fully pre-alloyed grades, for an injection yoke by wrought steel authors. Astaloy CrA (1.8% Cr) and Astaloy CrM processing and by PM, using two The leaner Ni-alloyed material high- (3% Cr, 0.5%Mo). In the assessments different PM materials (Astaloy CrM + lighted was Hoganas AB’s Distaloy AQ, presented, Astaloy CrA was used as 0.3%C and Distaloy AE + 0.5%C), were containing diffusion-alloyed additions of a base for the elemental addition of assessed (Fig. 1). 0.5%Ni and 0.5%Mo. This material can either 1% Cu or 2% Ni. Warm compac- Firstly, the presented results achieve density levels over 7.3 g/cm3 tion of the material with the 2% Ni of these analyses showed the very when warm compacted and can achieve addition showed that a density level of significant advantage of PM over the very high levels of dynamic properties in around 7.25 g/cm3 could be attained wrought steel route in relation to the the heat treated condition, particularly compared with around 7.1 g/cm3 for Fig. 7 Effect of lubricant and graphite additions on Pore Free Fig. 8 Effect of lubricant and graphite levels on maximum green environmental impact factors (Fig. 2). after case hardening. room temperature compaction. Density (PFD) [2] (Courtesy MPIF) density [2] (Courtesy MPIF)

Fig. 9 Effect of compaction temperature and pressure on green Fig. 10 Compressibility and green strength (Material FN-0205) density [2] (Courtesy MPIF) [2] (Courtesy MPIF)

Fig. 14 Influence of lubricant content on achievable green density over a range of (cold) compaction pressures [4] (Courtesy MPIF)

7.5 g/cm3, depending on alloy and The presentation was concluded Methods of achieving high graphite content and compaction with the revelation that, in such a density in PM structural pressure as demonstrated in Figs. 8 prototyping trial on a batch of ~2,000 and 9. Using a compaction pressure of parts, a weight control of +/- 0.3% parts 830 MPa, a room temperature green was achieved, with no degradation in Francois Chagnon (Rio Tinto Metal strength of around 35 MPa can be surface finish of parts being observed. Powders, Canada), on behalf of achieved (Fig. 10). Green strength at In a separate presentation entitled his co-authors, Sylvain St. Laurent the warm compaction temperature “Advanced High-Performance Gear (Rio Tinto Metal Powders) and was assessed as being around Processing via PM” later in the Yannig Thomas (Industrial Materials 20 MPa. Special Interest Program, Francis Institute) gave the company’s views An ability was demonstrated to Hanejko underlined the importance on processing variants aimed at achieve a density of 7.4 g/cm3 with of achieving high “core” density in increasing the density of ferrous PM Fig. 11 Compressibility of FLNC-4408 and FLNC-4908 [2] Fig. 12 Comparison of ejection characteristics (for compaction at FLNC-4408 sinter-hardening material PM gear products that were to be parts and the influence of materials (Courtesy MPIF) 830 MPa) [2] (Courtesy MPIF) (Fig. 11). It was also shown that subject to surface densification. Data issues in these processes. ejection characteristics with AncorMax was presented on the effect of core The process variants covered were: dependent on the parameter Pore Free 225 at 0.25 wt% were equivalent to density of a PM gear on the achievable • Higher pressure cold compaction Density (PFD), defined as the density those with 0.75 wt% Acrawax (EBS), depth of densification (Fig. 13). It • Warm die compaction of a green compact if all of the porosity see Fig. 12. was concluded that a core density of could be removed, and that the Set against these advantages, a >7.35 g/cm3 is desirable. The use of • Densification through sintering low-density additions of lubricant and few part geometry limitations of this the AncorMax 225 lubricant system shrinkage graphite have a particularly negative approach were referred to: may therefore be a key contributor to Studies on the effect of lubricant impact on PFD (Fig. 7). • Limitations in part height are achieving this condition. content on compressibility in It was noted that the practical limit anticipated. Parts over 25 mm in of green density is around 98% of PFD height may not be practical. This as, beyond this limit, micro-lamina- limitation could be overcome by tions can be formed during compac- increasing lubricant level, but tion. The means of approaching this this would be at some sacrifice in limit with AncorMax 225 were: green density. • To use the lubricant at as low an • Larger parts may not be prac- addition level as 0.25 wt%. tical, because of short die contact Fig. 13 Effect of core density on depth of densification in surface cold rolling of PM • To utilise warm die compaction time and inefficient thermal gears [3] (Courtesy MPIF) and an increased compaction transfer. pressure to increase material • The relatively high compaction high-pressure warm die compaction, as a “new lubricant system”. The compressibility. pressures, required for optimum was capable of enhancing the density lubricant system has now been given AncorMax 225 is used in an compaction, of >550 MPa may not of PM structural part materials to a the trade name AncorMax 225, will ANCORBOND premix (i.e. the lubricant be practical for parts that need level approaching 7.5 g/cm3. be launched commercially during the is also operating as a binder for thin or fragile punches in the third quarter of 2013 and considerably alloying additions), containing 0.25 forming tooling. New lubricant system more detail was given on its attributes wt% total lubricant with an optimum However, for applications within In a presentation last year at in this presentation. part ejection temperature of ~107°C these geometrical constraints, PowderMet 2012 it was reported that The basis for this lubricant system (225°F), hence the “225” designation. encouraging prototyping trials have Fig. 15 Effects of lubricant content and compaction stroke rate on green density [4] this lubricant was still in the develop- development was the recognition that It has been demonstrated that been carried out. (Courtesy MPIF) ment phase and was referred to only maximum achievable green density is maximum green density can approach

Fig. 16 Increase of density during sintering [4] (Courtesy MPIF) Fig. 17 Increase of green density with compaction temperature [4] (Courtesy MPIF) Fig. 20 Contact fatigue strength of sintered steels [5] Fig. 21 Contact stress requirements for a range of cam applications [5] (Courtesy MPIF) (Courtesy MPIF)

Fig. 18 Super Solidus Liquid Phase Sintering [4] (Courtesy MPIF) Fig. 19 Densification and dimensional change control in sintering of malleablised iron [4] (Courtesy MPIF) Fig. 22 Effects of various technologies in enhancing properties [5] (Courtesy Fig. 23 Roller one-way clutch race [5] (Courtesy MPIF) MPIF) cold compaction have led to the In subsequent sintering, it was Using this approach, full density conclusions that: observed that the gain in density PM materials can be produced with • At low compaction pressure, e.g. between the green and sintered states dimensional change tolerances of 550 MPa, powder compressibility increased with compaction pressure +/- 0.1%, when parts are properly plays an important role in control- (Fig. 16), indicating that a loss of sintered in the sintering temperature ling maximum achievable density, density due to larger springback window (Fig. 19). Green density is the while the effect of lubricant at higher compaction pressures is most important parameter to control content is marginal (Fig. 14) recovered during sintering. in order to maintain good sintered • At 950 MPa compaction pres- dimensional tolerances. Powder temperature sure, where the 98% of pore-free Tensile strength of 770 MPa, yield density limit is being approached, The effect of powder temperature in strength of 520 MPa and an elongation lubricant content becomes the Warm and Warm Die Compaction is, in value of 2.5% and axial fatigue strength most important factor limiting part, related to the effect of tempera- of 275 MPa can be achieved with a achievable green density while the ture on the yield strength of plain iron. pearlitic microstructure, using this effect of powder compressibility It was shown that 65-75% of the poten- sintering technology, the author stated. becomes more marginal (Fig. 14) tial density gain can be achieved when Fig. 24 Stress distribution in roller one-way clutch race [5] Fig. 25 2nd speed manual transmission gear [5] (Courtesy MPIF) compaction temperature is raised to (Courtesy MPIF) • The development of new poly- as low a value as 70°C (Fig. 17). meric lubricants with improved High-density technology for with particular reference to automatic properties were shown to clearly tions) is around 1400 MPa at typical lubrication efficiency makes it Sintering densification future PM growth transmission clutch race and manual depend on density; trend lines for press densities of 7.3 g/cm3 (Fig. 20). possible to reduce their contents The influence of sintering densifica- A presentation by Rajesh Para- transmission gear applications. contact fatigue and bending fatigue for Comparison of this value with the in powder mixes, therefore tion was considered in the context of meswaran (PMG Indiana Corporation, conventional PM materials could be contact fatigue requirements of a increasing pore-free density and the Super Solidus Liquid Sintering USA), on behalf of his co-authors, Conventional press and sinter used to predict mechanical properties range of applications (one-way clutch achieving higher green densities mechanism (Fig. 18) and included the Salvator Nigarura and Michael Bird, The presentation began with a review for fully dense wrought steel. This races, light and heavy duty cam lobes) with good ejection behaviour. concept of malleabilisation of high provided the company’s view on the of the capabilities of conventional review culminated in the conclusion lead to the conclusion that convention- • Green density decreases with the carbon iron powder as presented at potential for higher performance press/sinter PM processing in relation that the maximum achievable contact ally processed PM materials cannot height of the part and with compac- the 2012 World Congress (see Powder applications to be unlocked by the to applications, density levels and fatigue strength (a property key to the satisfy the requirements for torque tion rate (Fig. 15) Metallurgy Review Vol. 2 No. 1 pp49). use of higher density process options, mechanical properties. Mechanical target higher performance applica- convertor outer race cams (Fig. 21).

concluded that the key to success here to the main competing technology of aimed at offering higher strength and • Other vanadium micro-alloyed is surface densification with moderate open die drop forging. at attacking PF’s perceived competitive grades, 46MnVS6mod (0.46%C, core density. In the presentation by Ilia the advantage of big-end cap fracture 0.63%Si, 1.02%Mn, 0.26%Cr, The influence of DensiForm® on comparison of the two competitive splittability, explained Ilia. This 0.20%Ni, 0.13%V and 70MnVS- bending fatigue strength is summa- process routes was set in the context material, a modified C70 (AISI 1070) 4high (0.70%C,0.20%Si, 0.83%Mn, rised in Fig. 26 in comparison with of their relative responses to the grade, raised carbon content from the 0.15%Cr, 0.14%Ni, 0.19%V) PM materials with a range of bulk increasing demand from automotive previous norm of 0.4-0.5% to 0.7%. The • A material, developed by densities, including fully dense Powder OEMs for higher strength connecting effects of this carbon content increase Hyundai, in which the carbon Forged material, and with wrought rod materials in order to enable the were to increase strength, to confer content in C70S6 was reduced steel. In the case-hardened condition, light-weighting of rods or the use fracture splittability, but to sacrifice and the silicon content was DensiForm® delivers a bending fatigue of a given size of rod in a higher some machinability. increased. Vanadium was also strength somewhat lower than Powder performance engine. More recent developments in DF added to this grade to increase Forging or a wrought steel route, connecting rod materials have been strength. but, at >1000 MPa, the level achieved Evaluation of mechanical properties aimed at further strength enhance- The tensile properties of several of is substantially higher than the Ilia first described the range of higher ments, retention of fracture splitta- these high strength PF and DF grades maximum bending stress experienced strength material grades that have bility and, in some cases, attacking the were measured on test-pieces taken by the 2nd speed gear. emerged from the Powder Forging (PF) machinability limitation. These grades from the I-beam sections of forged For higher speed manual transmis- industry’s response to this challenge. have included: connecting rods as shown in Fig. 27. sion gears, it was again concluded These have included: • 36MnVS4, a material with The results of these tensile tests that surface densification with a • New optimised grades introduced lower carbon content to aid are shown in Table 1 and Fig. 28. As higher core density may be the key to by Metaldyne themselves, with machinability and with a micro- can be seen from these results, these attacking this market. copper contents ranging from 3 alloying addition of vanadium and high strength grades were mainly ® Fig. 26 Competitive position of DensiForm in enhancing bending fatigue strength [5] to 3.5% (HS150M, HS160M and increased molybdenum content to quite comparable with one another in (Courtesy MPIF) Powder forging HS170M), that have higher and increase strength terms of tensile properties. demonstrates superiority more consistent mechanical An emphasis on surface densification principal stress and normal contact properties than the previous in the connecting rod Area A need for densification was therefore stress fall by 54% and 77% respectively standard 2%Cu material Elongation UTS (MPa) YS (MPa) Reduction defined and, based on the recognition over the first 1 mm from the surface. competition (%) • Materials developed by GKN (%) that the stress fields in the targeted In relation to the “core” strength An extremely up-beat presentation on that use a base iron powder applications are highly localised in the requirements, it was concluded that the superiority of the Powder Forging HS170M 1,209 864 10% 19% pre-alloyed with 3% copper to surface layers of the component, the higher core density is a key to success route was provided by Edmond Ilia homogenise the strengthening 3-PA [9] 1152 877 9% N/A emphasis was on surface densification with highly loaded applications. (Metaldyne LLC, USA) on behalf of his effect of the copper. Additional methods, in particular the company’s Turning to manual transmission co-authors Kevin T Tutton and George Sinteron CRL 970 746 10% 17% copper can be introduced into this proprietary DensiForm® technology. gear applications, the example was Lanni. base material, as desired, through HPF110 (Development) 1158 840 6% N/A Fig. 22 shows schematically the effect considered of a 2nd speed helical gear Practically ever since the emergence an elemental addition of DensiForm® technology on bending (Fig. 25). The nature of the stress field of Powder Forging as a viable means of S1-FC [11] 1091 843 12% N/A fatigue and contact fatigue strength, for this type of component requires manufacturing automotive connecting • A material, introduced by Sinteron 46MnVS6mod [12] 1157 849 10% 32% as compared with bulk densification high strength near the surface and rods some 35 years ago, there has been in collaboration with Höganäs AB, PM technologies and in the context of moderate strength in the core. It was continuing debate on its merits relative that is based on the pre-alloyed 70MnVS4high [12] 1217 823 9% 19% wrought steel performance levels. Astaloy CrL grade. The Drop Forging (DF) industry’s Table 1 Comparative tensile properties of selected high strength PF and DF grades [6] Growth opportunities initial material development was (Courtesy MPIF) Growth opportunities were highlighted in components such as: FS at 50% FS at 90% FS at 10% Scatter Stress Number of Material Cycles SR SR SR Material Ts • Torque convertor races for ratio r Tests automatic transmissions (MPa) (MPa) (MPa) (MPa) • Lower speed gears for manual C70 -1 10M 326 252 400 58 1.59 20 transmissions. C70 -2 10M 345 283 406 48 1.43 20 Torque converter races in particular call for: C70 -1 10M 288 252 323 28 1.28 25 • Contact stress >2500 MPa 36MnVS4 -2 10M 353 258 448 74 1.73 15

• Maximum tensile stress >700 MPa 36MnVS4 -1 10M 358 337 372 11 1.10 16 • Von Mises >1800 MPa. 36MnVS4 -1 10M 328 308 347 15 1.13 15 In the example cited of an outer race for a torque convertor roller 36MnVS4 -1 10M 370 339 402 25 1.19 20 one-way clutch (Fig. 23), rollers 36MnVS4 -2.5 10M 460 431 489 23 1.14 20 lock-up against cam and race under torque with high stress (hoop and 36MnVS4 -2.5 5M 412 402 422 8 1.05 20 contact) at full torque (Fig. 24). Surface 70MnVS4 -2.5 5M 427 337 518 71 1.54 18 densification can be effective with Fig. 27 Cylindrical specimens machined from the I-beam of PF connecting rods this type of application as maximum manufactured with HS170M [6] (Courtesy MPIF) Table 2 Published fatigue data for DF con-rods [6] (Courtesy MPIF)

New materials for connecting rods Fatigue performance r= -1

Fig. 32 Manufacturing defects observed in DF con-rods [6] (Courtesy MPIF)

there is no requirement to allow for draft angles or trim lines, the I-beam

MPa Fatigue Strength Fatigue Strength Scatter section of a PF rod is smoother than a Fig. 28 Tensile properties for high strength con-rod materials [6] at 50% SR at 90% SR DF rod (Fig. 33). Also, the inner radius (Courtesy MPIF) 36MnVS4 370 339 25 in the web can be smaller for a PF HS170M 451 441 8 rod, making possible a better mass distribution in the outer corners of Fatigue performance r= -2.5 Fig. 30 Comparative axial fatigue performance of DF and PF the section where its contribution to con-rod grades at R = -1 [6] (Courtesy MPIF) stiffness is higher, added Ilia. In the conclusion to the presentation other competitive advantages Powder Forging Advantage: Fatigue test results - variation of PF rods over DF rods were enumerated by Ilia (although without • No trim line or draft angle • Mass reduction opportunity supporting quantitative data): • 5% higher stiffness in (reduced cross-section) XX-direction without loss of stiffness • Higher material utilisation • 15% higher stiffness in • Better weight variation control YY-direction (of significance in relation to NVH considerations) Fig. 33 Ilia suggested further opportunities for light-weighting with PF con-rods [6] • Better machinability (Courtesy MPIF) • Reduced numbers of machining Fatigue Strength Fatigue Strength MPa Scatter operations at 50% SR at 90% SR PowderMet2013, MPIF, USA Acknowledgements 36MnVS4-1* 460 431 23 • Lower deformability during the [3] F J Hanejko, Advanced High- 70MnVS4 * 427 337 71 fracture splitting process Performance Gear Processing via PowderMet 2013 was organised by the HS170M 494 485 8 • Lower overall cost in the finished PM, as presented at PowderMet2013, Metal Powder Industries Federation. machined product MPIF, USA For more information please visit the MPIF website: www.mpif.org Fig. 29 Comparative axial fatigue performance of DF and PF Fig. 31 Comparison of fatigue strength scatter for PF and DF Overall, the presentation provided [4] F Chagnon, S St. Laurent, Y grades at R = -2.5 [6] (Courtesy MPIF) con-rods [6] (Courtesy MPIF) compelling reasons for choosing the Thomas, Methods of Achieving High Powder Forging route. Density to Develop New PM Applica- Author tions, as presented at PowderMet2013, Dr David Whittaker is a consultant to Fatigue performance of connecting probability of survival value is the The low level of scatter and, hence, MPIF, USA the Powder Metallurgy and associated rods most commonly used parameter in of required safety factor, gives the PF References [5] R Parameswaran, S Nigaruga, industries. Ilia stated that a much more inter- connecting rod design and the degree grades a significant edge in terms of [1] U Engström, C Larsson, S Berg, M Bird, High-Density Technology Tel: +44 (0)1902 338498 esting comparison emerged in terms of scatter controls the level of safety the capability for light-weighting in C Szabo, Key Aspects, from Raw for Future Powder Metal Growth email: [email protected] of axial fatigue properties, which is a factor that must be applied to the design, he said. Material to New Challenging Applica- Opportunities, as presented at more relevant comparison as fatigue resulting design. Scanning electron microscopy tions, to Create Future Growth of PowderMet2013, MPIF, USA is the critical criterion in designing The superiority in fatigue studies of fracture faces after fatigue the PM Industry, as presented at [6] E Ilia, K T Tutton, G Lanni, Overview connecting rods. performance of HS170M over that of testing revealed the underlying reason PowderMet2013, MPIF, USA of Properties of the Materials Used In these tests the fatigue strengths 36MnVS4, in terms of both strength for the high scatter in strength of DF [2] F J Hanejko, S Clisby, High- to Manufacture Connecting Rods, as of the DF grades 36MnVS4 and at 90% probability of survival and of rods, stated Ilia. These studies revealed Density Compaction Using Lubricant presented at PowderMet2013, MPIF, 70MnVS4 were compared with the PF degree of scatter, was even more the presence of forging defects, Levels of 0.25 w/o, as presented at USA grade, HS170M. marked in fully reversed (R= -1) tests, particularly along the trim line, such as Ilia stated that the results of tests as demonstrated in Fig. 30. oxides, folds and micro-cracks (Fig. 32), conducted using the staircase method, The observed high level of scatter which can act as crack initiators. as defined in MPIF Standard 56, and at in fatigue performance is quite typical a stress ratio, R, of -2.5, demonstrate of reported data on drop forged Design advantages the superiority of HS170M in terms connecting rods, stated Ilia (Table 2). A further source of potential weight both of the fatigue strength at 90% The comparative variations in fatigue reduction in PF rods was revealed in probability of survival and of the test results, reported for PF and DF discussing issues related to “design scatter in results (Fig. 29). The 90% rods are shown graphically in Fig. 31. for the process.” For instance, because

MPIF 2013 award winning Powder Metallurgy parts showcase an innovative industry

Winning parts in the Metal Powder Industry Federation’s (MPIF) 2013 Powder Metallurgy Design Excellence Awards competition were announced at the PowderMet 2013 International Conference on Powder Metallurgy and Particulate Materials, Chicago, June 24-27. The awards provide a showcase for Powder Metallurgy, demonstrating the latest design and manufacturing developments in the industry.

It is clear from this year’s MPIF Grand Prize Awards Made via the MIM process, these Awards that conventional press components are used in a sensor kit and sinter Powder Metallurgy (PM) Automotive engine that measures the inlet pressure of technology is continuing to find Indo-US MIM Tec Pvt. Ltd., Bangalore, the air fuel mixture in each cylinder of ipmd.net India, received a grand prize in the new applications in many sectors, a passenger car engine. The length of whilst also replacing traditional automotive engine category for a the threaded port creates complexity, manufacturing processes thanks sensing element, a threaded port, as do the thin walls and fragile to the design, performance and and a support ring made for Sensata features, and the stringent customer Your on-line source for PM industry economic advantages that Powder Technologies Holland B.V., Almelo, the requirements on visual aspects add to Metallurgy offers. Netherlands (Fig. 1). the difficulty of manufacture. The continuing growth in the news, technology and more.... Metal Injection Moulding (MIM) industry is also evident, reflected in the large number of prizes presented to this sector in this year’s awards. MIM’s growing acceptance in the Sign up for our FREE weekly PM e-newsletter automotive industry as a trusted manufacturing route is clear, with today at www.ipmd.net/enews both a Grand Prize and Award of Distinction being presented to MIM companies in this demanding sector. The MIM process was also the manufacturing method of prize winners in the hand tools/recreation, aerospace/military and medical/ dental categories. Fig. 1 These MIM components are used in a sensor to measure the inlet pressure of the air fuel mixture in each cylinder of a passenger car engine (Courtesy MPIF) Scan the QR code to visit www.ipmd.net

Made of carbon steel, this single strength. The parts are compacted to Aerospace/military level part is pressed to a density net shape and require no secondary Polymer Technologies Inc., Clifton, of 6.85 g/cm³, sintered, and then operations. New Jersey, USA, were presented re-pressed to 7.00 g/cm³. Other final They belong to a new generation with the grand prize in the aerospace/ properties include ultimate tensile of DC motors using soft magnetic military category for two MIM parts, a strength of 30,000 psi, 20,000 psi composite PM materials to enable U-bracket and stop used in a Feedbox min. yield strength (2% offset), and greater design freedom for designers Support Improvement Kit (FSIK) for an 75 HRF min. hardness. The 7.795 in. of electric machines. M249 squad automatic weapon (SAW) dia. is held within 0.006 in., while the used by the US Military (Fig. 6). angularity of the 40 teeth is maintained Hand tools/recreation The device is designed to hold within ±1 degree. The 805 g part is Indo-US MIM Tec Pvt. Ltd., Bangalore, various size high volume magazine pressed to net shape, with the drilling India, received the grand prize in ammunition packs securely to the of the five true position holes being the the hand tools/recreation category gun. It extends the service life of the only secondary operation. for a tool holder assembly made for weapon by enabling the soldier to In addition to the saving of 63% Scintilla AG, Solothurn, Switzerland. repair it in the field, thus avoiding the over the cost of machining, the The assembly that incorporates these cost of a new weapon. critical thickness, flatness, and two MIM parts, a tool holder and a Drop testing of the firearm with parallel tolerances maintained in its the device attached proved the Fig. 2 Compressor clutch used in a braking system for heavy Fig. 4 These parts are used to generate a magnetic flux in a high grip spring tensioning part, goes into manufacture make the rotor a truly integrity of the FSIK even while other trucks and buses (Courtesy MPIF) efficiency brushless DC motor (Courtesy MPIF) a woodworking tool for fine detail outstanding PM part. carving (Fig. 5). components were damaged. The Part complexity made MIM the innovative I-beam and webbing design Hardware/appliances obvious choice as no other technology allowed the parts to meet the 32–38 Claw pole motor core stators made could produce the part as an integral HRC hardness range requirement and by Burgess-Norton Mfg. Co., Geneva, unit and deliver it in the needed still maintain the total weight of the Illinois, won the grand prize in the volumes at the target cost. Made kit below 3.5 oz. hardware/appliances category. The of a low alloy steel, the parts are Moulded from MIM-17-4 PH parts are used to generate a magnetic supplied in the heat treated condition. stainless steel, the parts have >7.5 g/ flux that interacts with a rotor and Properties include 7.5 g/cm³ minimum cm³ density, 130,000 psi ultimate permanent magnets to produce torque density, 225,000 psi ultimate tensile tensile strength, 106,000 psi yield in a high efficiency brushless DC strength, and 200,000 psi yield strength, and 6% elongation. The motor in an electric ceiling fan (Fig. 4). strength. To overcome the possibility only secondary processing of these Both halves of the motor core of distortion on the unsupported open near net shaped parts are a coining are produced using one set of tools: end, the design provided supporting operation to the bracket in order to heated fixed fill shelf die, core rod, ribs. The grip support ring was achieve the tolerance required for the single upper punch, and six thin walled produced per print with the help of one distance between the notch and the lower fill punches. Formed from a high turning operation. through hole, as well as tapping the compressibility inorganically insulated The MIM design contributes to hole to provide necessary threading. iron powder, the parts are compacted a lean operation for the customer Both parts are black oxided to remove Fig. 3 Transmission rotor part used in large off highway Fig. 5 MIM tool holder assembly for a woodworking tool used in with pressures exceeding 67 tsi to a by substantially reducing lead time their reflective properties, a critical construction vehicles (Courtesy MPIF) fine detail carving (Courtesy MPIF) density range of 7.4–7.5 g/cm³, typical through the elimination of many consideration for the safety of the ultimate tensile strength of 7,000 psi, processing steps. soldier. and 19,000 psi transverse rupture Made of MIM-17-4 PH stainless trucks and buses (Fig. 2). part, other than the outer grooves, steel, the parts have a heat treated The system stops the compressor is reached directly from compacting. yield strength of 160,000 psi, ultimate once the necessary air pressure is Secondary processing includes sizing, tensile strength of 178,000 psi, 7% reached, which saves energy and helps turning, drilling two blind holes, and elongation, 35–40 HRC hardness reduce the vehicle’s fuel consumption several finishing steps. range, and 7.6 g/cm³ density. The parts by 7%. Made of a diffusion alloyed PM was the only technology are formed close to net shape, with steel, the complex part is compacted capable of producing this part at the only coining and passivation required on a CNC 400 mt press at a pressure customer’s cost target. on all three, plus CNC thread cutting of >87,000 psi to achieve a required on the port only. density >7.0 g/cm³. Other properties Lawn & garden/off highway This new application is estimated include 66,000 psi yield strength, Capstan Tennessee Inc., Rockwood, to save the customer 50% over the 103,000 psi ultimate tensile strength, Tennessee, USA, was given the cost of manufacture using alternative 1% elongation, and 85 HRB hardness. grand prize in the lawn & garden/off technologies. The PM design integrates into a highway category for a transmission single component what was originally rotor made for Caterpillar Inc., Automotive chassis designed as two separate toothed Peoria, Illinois. The rotor mates with AMES S.A., Barcelona, Spain, parts - the conical front, which a magnetic sensor that reads the was awarded a grand prize in the connects to the crankshaft, and the rotating teeth to generate speed data automotive chassis category for a opposite face, which connects to used for controlling the shift point the compressor and a coupling. The compressor clutch that is part of an of transmissions powering large off Fig. 6 MIM parts for a component used in the M249 squad Fig. 7 Stainless steel jaw made for a medical grasping device full shape of the large (nearly 1 kg) assembly in a braking system for heavy highway construction vehicles (Fig. 3). automatic weapon used by the US Military (Courtesy MPIF) (Courtesy MPIF)

Medical/dental achieve full functionality with the sharp Awards of Distinction FloMet LLC/A QMT Company, Deland, talons and teeth at net shape. The Florida, USA, was awarded the grand parts have >7.5 g/cm³ density, 130,000 Automotive engine prize in the medical/dental category psi ultimate tensile strength, 106,000 Indo-US MIM Tec Pvt. Ltd., Bangalore, for a 17-4 PH stainless steel jaw made psi yield strength, 6% elongation, India, won the first award of distinction for US Endoscopy, Mentor, Ohio, and and 27HRB hardness. Only minimal in the automotive engine category for used in a Raptor™ grasping device secondary processing (coining to help a fuel control gear segment made for (Fig. 7). maintain the alignment of the jaws) Bosch Limited, Bangalore, India (Fig. Made via MIM, the jaws merge was needed, as other geometries and 8). The part goes into a fuel control into one design that features both tight tolerances were achieved in the device that regulates the entry of fuel a rat tooth jaw and an alligator jaw, as moulded condition. into the engine. combining the functions of a grasper Alternative processing methods Converted from a machined part, and a retrieval forceps that surgeons could not have achieved the part’s the gear segment is fabricated via use to retrieve foreign objects in intricate geometries at a reasonable MIM from a low alloy steel at a saving the body during minimally invasive cost. MIM is estimated to have saved of 80% over the previous method. procedures. more than 60% over die casting or Moulded to net shape and requiring The component design is machining the parts. no secondary operations, the part enormously complex due to its small has a density of 7.5 g/cm³, 46,000 psi size, thin wall requirements 0.25 mm ultimate tensile strength, 19,000 psi Fig. 12 The rack, pinion, and bushing are components used in a Fig. 13 This MIM actuator is used in a tool less locking system (0.010 in.), and features required to yield strength, 25% elongation, and pergola louver system (Courtesy MPIF) that enables quick changing of a shotgun stock (Courtesy MPIF)

100 HRB max. hardness. Nearly three Made using FL-4400 prealloyed hardness. Aggressive PM part design million pieces are delivered annually to steel, the parts are pressed, sintered, yielded 40% savings over alternative the customer. soft turned, heat treated (Q&T) and methods. then hard turned to generate concave Automotive engine back face features. Unique processing Hardware/appliances GKN Sinter Metals LLC, Conover, and part density enable the production FMS Corporation, Minneapolis, North Carolina, USA, won the other of a component that exhibits the Minnesota, USA, also won an award of award of distinction in the automotive strength and wear properties of distinction in the hardware/appliances engine category for an aluminium FL-4405-125HT on the ramp face and category for an assembly consisting rear cam cap (Fig. 9). Used in a new soft magnetic properties on the back of a rack, pinion, and bushing used automotive engine, the part serves a face. in a patented pergola louver system dual function of holding the camshaft The use of PM provided cost savings that allows the pergola to convert to a in place as well as holding an auxiliary estimated at 20-40% over machining water tight shelter (Fig. 12). vacuum pump. a component with similar functional The sinter hardened steel rack and This is the first time an aluminium performance. five level pinion and the copper steel cam cap with the unique tombstone bushing are pressed to net shape with geometry has been manufactured Hardware/appliances one cross drilled hole being the only via press and sinter PM. Until the ASCO Sintering Co., Commerce, secondary operation performed. The present redesign, in which the part is assembly was designed to be sinter Fig. 8 Fuel control gear segment of a fuel control device that Fig. 10 This ramp plate is used in an electronically activated California, USA, won an award of compacted inverted, this feature could bonded for strength. regulates the entry of fuel into the engine (Courtesy MPIF) locking differential in light commercial vehicles (Courtesy MPIF) distinction in the hardware/appliances only be formed via die casting. category for an inside hub adaptor, The parts have a typical density of The part is formed to near net made for Ingersoll Rand Security 6.7 g/cm³, 75,000 psi ultimate tensile shape with only the cover seal area Technologies (Schlage), Carmel, strength, 135,000 psi transverse being CNC machined. Properties Indiana (Fig. 11). The copper infiltrated rupture strength, and 20 HRC min. include 2.55 g/cm³ density, 22,000 psi PM steel part is used in modern, apparent hardness and 52 HRC min. ultimate tensile strength, 17,000 psi high end electronic commercial and particle hardness. Because of yield strength, and 60 HRE min. residential door lock systems including the large number of assemblies apparent hardness. the latest touch screen devices. required in each louver system, the The part has seven functional PM process gave the customer the Automotive transmission levels that are pressed using three only cost effective option, delivering The award of distinction in the upper punches, two separate shelf an estimated 75% savings over the automotive transmission category levels, and two lower punches, with machined alternative. was won by Burgess-Norton Mfg. Co., a proprietary triple upper actuating Geneva, Illinois, USA, for a ramp plate mechanism used to achieve Hand tools/recreation used in an electronically activated extensive powder transfers and fill An award of distinction in the hand locking differential in European light compensation. The adaptor is pressed tools/recreation category was earned commercial vehicles (Fig. 10). These to net shape with plating as the only by Parmatech Corporation, Petaluma, differentials significantly improve on secondary operation performed. California, USA, for an actuator used in demand vehicle traction in adverse Properties include 7.7 g/cm³ density, a tool less locking system that enables conditions by directing 100% of the 95,000 psi ultimate tensile strength, quick changing of a shotgun stock Fig. 9 Aluminium rear cam cap used in a new automotive engine Fig. 11 This copper infiltrated PM steel inside hub adaptor is drive torque simultaneously to both 8% elongation, 100 ft.∙lb. unnotched (Fig. 13). design (Courtesy MPIF) used in electronic door lock systems (Courtesy MPIF) wheels. Charpy impact energy, and 90 HRB Made via MIM of a low alloy steel,

Soft Magnetic Composites in the development of a new compact transversal flux electric motor

With growing demand for electric motors used in practically all sectors, the number of applications for sintered and non-sintered Soft Magnetic Fig. 14 A star shifter used in a six speed motorcycle transmis- Fig. 15 MIM stainless steel shuttle used in a stapling device for Composite (SMC) materials based on soft magnetic iron powders is sion system (Courtesy MPIF) arthroscopic surgery (Courtesy MPIF) increasing significantly. GKN Sinter Metals and RWTH Aachen have collaborated to develop a new transversal flux motor (TFM) which the complex design part required the enables the engagement and shifting compressive force for the surgeon uses SMC iron powders in the stators of the motor. We report on a use of stepped ejector pins on the among all the gear combinations. using it. sloped surface to allow for smooth This six level part is made of sinter Manufactured via MIM, the presentation given by Stefan Tiller, GKN Sinter Metals, at the Coil ejection with no part damage. It has hardened steel, moulded in a CNC shuttle incorporates two separate Winding Expo, Berlin, Germany, June 26-28 2013, on the development of a 0.05 mm (0.002 in.) straightness servo controlled, multi action hydraulic components that previously were the new TFM e-motor. requirement of the longer than 25.4 press to a typical density of 6.65 g/ combined via laser welding. Making mm (1 in.) shaft and a tight profile cm³. Other properties include 75,000 this intricate, small, and lightweight requirement of the curved and sloped psi ultimate tensile strength, 135,000 0.175 oz. component presents many cosmetic surface. The part is moulded psi transverse rupture strength, and 20 challenges, including the extremely and sintered close to net shape to 7.48 HRC min. apparent hardness and 52 thin walls, tight radii, and true position g/cm³ density, and is coined in order to HRC min. particle hardness. geometries, especially the two leg tips, achieve repeatability. The customer estimates a 45% cost which need to maintain their required Choosing MIM over casting and savings over the previously forged part. strength and piercing sharpness. Part machining the part provided a cost properties include 7.75 g/cm³ density, savings of 25–35%. Medical/dental 200,000 psi ultimate tensile strength, Transversal flux motors (TFMs) powder. The new TFM motor, which industry standard brushless radial Polymer Technology Inc., Clifton, 160,000 psi yield strength, 11%-30% and their applications in direct was introduced for the first time at the flux motor of a current white goods Hand tools/recreation New Jersey, USA, received the award elongation, and 82 HRB hardness. drive systems is a relatively recent Coil Winding Expo – CWIEME in Berlin application, yet creates higher power A star shifter made by FMS of distinction in the medical/dental The shuttle is formed to nearly development in electric motors which in June 2013, is around 50% smaller density. Corporation, Minneapolis, Minnesota, category for a stainless steel shuttle net shape, requiring only minimal demand high torque at low speed and and uses 40% less copper than an In its basic form the TFM prototype USA, for Polaris Industies, Wyoming, used in a smart stapling device for secondary operations of reaming and where the elimination of a gearbox can Minnesota, and used in its Victory both open and minimally invasive then tapping the small hole, as well as result in a compact design, reduction motorcycle transmission, won another arthroscopic surgery (Fig.15). providing proprietary sintering fixtures in iron losses, and less maintenance. award of distinction in the hand tools/ It is part of a device that interacts to maintain the straightness callout for TFMs can offer a high percentage size recreation category (Fig. 14). with a disposable staple cartridge the parallel walls. reduction compared with conventional The first PM component in this six in a computer controlled device that e-motors, and with only small masses speed transmission, it functions as provides a high level of precision, rotating in the rotor supported by axial the cam interface in a mechanism that consistency, accuracy, agility and magnetic forces, the result is also a low-noise electric motor. Another benefit is the reduction of the copper content in TFMs which leads to lower costs as well as less weight compared with traditional radial flux motors and the popular axial flux motor (Fig. 1) GKN Sinter Metals has been working to produce a new prototype transversal flux motor under a development project called Elektra, supported by the RWTH University of Aachen, Germany, in which GKN Sinter Metals uses a stator produced out of Soft Magnetic Composite (SMC) iron Fig. 1 Comparisons of various electric motor concepts [1] (Courtesy GKN Sinter Metals)

Fig. 6 Complex geometry of the SMC stator produced by GKN Fig. 7 Assembly of a 3-phase Elektra transversal flux motor Sinter Metals to high dimensional accuracy for use in the using six SMC stators [1] (Courtesy GKN Sinter Metals) Fig. 2 Basic design of the transversal flux motor developed Fig. 3 Each SMC iron powder particle is given an electric isola- Elektra TFM [1] (Courtesy GKN Sinter Metals) jointly by RWTH Aachen University and GKN Sinter Metals [1] tion layer [1] (Courtesy GKN Sinter Metals) (Courtesy GKN Sinter Metals) produce the stator cores for the TFM stator with pre-wound copper coil including SMCs are new e-bike prototype showed high maximum being directly placed into the stator motors, water and oil pumps, small saturation induction of 1.6 to 1.7 using simple circular winding. The generators, starter motors, fan motors T at the density of 7.5 g/cm3, high simple winding method eliminates for vehicles and further domestic white permeability (650) and had low iron expensive copper wiring equipment, good appliances, to name just a few. losses (91.8 W/kg at 1 kHz (0.75T)). makes full use of the copper by The isotropic magnetic properties enabling a high packaging rate and For more informaton visit: and low eddy current losses of leaves no dead copper in the system. www.gkn.com/softmagnetic three dimensional transversal flux machines is achievable only by using “Key design advantages of the PM route SMC powder materials. The influence of different section densities in the in producing the TFM stators is the SMC stator also increases magnetic efficiency by gearing the magnetic flux ability to design magnetic circuits with density. three-dimensional magnetic flux paths to Fig. 4 Eddy current losses 1 kHz and permeability of three SMC Fig. 5 Microstructure of SMC compacts showing the isolation grades used by GKN Sinter Metals for soft magnetic compo- coatings [1] (Courtesy GKN Sinter Metals) Design advantages overcome the restraints imposed on the nents [1] (Courtesy GKN Sinter Metals) Key design advantages of the Powder magnetic field by steel laminations” Metallurgy route in producing the TFM developed by GKN Sinter Metals and Their frequencies can range from 100 electric isolation layer ~0.001 mm stators is the ability to design magnetic RWTH Aachen consists of a stator Hz up to theoretical 20 kHz. thick (Fig. 3). The eddy current losses circuits with three-dimensional These are then assembled onto an References element made from one of the SMC and permeability properties of GKN magnetic flux paths to overcome the assembly shaft with a permanent [1] From presentation by Stefan Tiller: grades used by GKN Sinter Metals, Soft Magnetic Composite SMC A grade and two other SMC restraints imposed on the magnetic magnet rotor, and the second stator is a copper winding and a rotor with a grades used by GKN Sinter Metals are field by steel laminations. This allows added to complete the 1st phase. The “New opportunities in the development NdFeB permanent magnet (Fig. 2). iron powders used in TFMs shown in Fig. 4. different topologies to be exploited for poke yoke design of the stator ensures of cost- and power-efficient electric In order to produce a TFM motor The Soft Magnetic Composite chosen GKN Sinter Metals uses a high electric motor performance. An perfect orientation of the phases motors using PM produced parts” at with an output of 1 kilowatt, three by GKN Sinter Metals to produce the compaction pressure of 75 kN/cm2 to other advantage is the high precision to each other. It is then possible to CWIEME 2013, Berlin, June 2013). phase elements have to be assembled stators is based on a high purity, high achieve a green density of 7.5 g/cm3 which can be achieved in the complex proceed with the 2nd phase, and in the GKN SMC A grade material. shape compacts (ISO Class 8) to optionally a 3rd phase can be added After pressing the compacts are heat reduce air gaps and to ensure better to increase the power of the Elektra “Higher performance can be achieved treated at temperatures between positioning and a smooth silent run. motor. 200 - 600 °C to anneal and cure The Elektra transversal flux motor When compared with a conventional with a modular design of several the bond, and to obtain mechanical development programme undertaken electric motor the Elektra TFM has a phases assembled in line. Their strength of approx. 125 N/mm2. As can jointly by RWTH Aachen and GKN significantly smaller motor volume, be seen in Fig. 5 the isolation layer Sinter Metals involved the evaluation of higher torque density, and, as frequencies can range from 100 Hz up remains intact in the microstructure a number of possible motor concepts. mentioned earlier, lower noise level to give three-dimensional (isostatic) This included three dimensional due to the harmonic frequency output to theoretical 20 kHz” magnetic properties in the SMC stator modelling of the various concepts of the Sinus pole geometry and also with significantly reduced eddy current and FEM simulation to determine low cogging characteristics. Scan this QR code to watch the anima- in line with a displacement of 120 compressibility iron powder grade, losses. Following curing the TFM magnetic performance and efficiency GKN Sinter Metals states that tion “New Generation Electric Motor with degrees each. Higher performance GKN SMC A, where each powder stators (Fig. 6) can be coated, steam of the electric motors. The result is potential e-motor applications below PM4EM” on YouTube. The video gives can be achieved with a modular design particle (<0.2 mm) is coated with a treated and machined, if needed. the 3-phase TFM shown in Fig. 7. This 1 kW, suitable for the advantageous detailed insight to the new “Elektra” of several phases assembled in line. resin-based material to create an The GKN SMC A material used to shows the assembly of the first SMC transversal flux and axial flux motors Transversal Flux Motor (TFM) project.

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Euro PM2013 Congress and Exhibition American Isostatic Presses, Inc. 24 September 15-18 Ametek 23 Gothenburg, Sweden www.epma.com APMA 2013 International Conference 56 Avure Technologies 15 APMA 2013 International PM Conference and Exhibition November 3-6 Codina 8 Xiamen, China China PM Business website 28 www.apma2013.com Da Chen Molding Co., Ltd. 27

Hagen Symposium (32nd) Dorst 1 November 28-29, 2013. Elnik Systems Inc. 21 Hagen, Germany Engineered Pressure Systems Int. N.V. 28 www.pulvermetallurgie.com Euro PM2014 Congress and Exhibition 49 2013 International Titanium Powder Processing, Fluidtherm 12 Consolidation and Metallurgy Conference December 2-4 Waikato, New Zealand Institut Dr. Foerster GmbH & Co. KG 20 www.tida.co.nz GGP Metalpowder AG 24 HIP 2014 International Conference 50 2014 Hoeganaes Corporation Inside Front Cover Höganäs AB 81 PM14 - International Conference on Powder Metallurgy Ipsen Inc. 4 and Particulate Materials & Exhibition Jayesh Industries Ltd. 26 January 23-25, Chennai, India www.pmai.in/pm14 Lonza Inc. 17 Loomis Products Kahlefeld GmbH 14 10th International Conference on the Science of Hard Materials (ICSHM10) Makin Metal Powders 9 March 10 - 14 Metal Improvement Company 25 Cancun, Mexico MIM2014 International Conference 40 www.icshm10.org PM China 2014 29 Let’s gear up together PM China 2014 - International Power Metallurgy PM 2014 World Congress 55 Exhibition & Conference Powder Injection Moulding International 78 April 27-29, Shanghai, China The Höganäs PoP Centre has recently been expanded by helical gear compaction capability as well as a low www.cn-pmexpo.com PVA TePla 19 pressure carburising (LPC) furnace for sintering and heat treatment. Together we can now further explore and Rio Tinto QMP 7 optimise materials, processes and design for PM transmission solutions. Our joint re-engineering of a 6-speed PM2014 World Congress manual transmission for 320 Nm torque is a perfect example. By fully utilising the advantages of the PM May 18–22 Ronald Britton Ltd 18 Orlando, Florida, USA Royal Metal Powders 13 process route, design of gear web, flank and tooth root can be optimised to reduce bending and impact www.mpif.org SACMI 11 stresses as well as noise characteristics.

HIP 2014, 11th International HIP Conference Taizhou Sanxin Cemented Carbide Co., Ltd. 16 Join us in Gothenburg to hear more about our latest development activities. June 9 -13, 2014 Shenzhen Gem High-Tech Co. Ltd 10 Stockholm, Sweden SMS Meer 32 www.hip14.se TD Molybdenum & Tungsten Manufacturing LLC 22 Euro PM2013 Congress & Exhibition 15th-18th September Sintering 2014 Timcal 5 Svenska Mässan, The Swedish August 24-28 Dresden, Germany Exhibition and Congress Centre Titanium Industry Development Association 39 www.sintering2014.co Stand no. 35 United States Metal Powders, Inc. 2 Gothenburg, Sweden