PMR Spring 2016 Vol. 5 No. 1

POWDER METALLURGY

VOL. 5 NO. 1 VOL. SPRING 2016 REVIEW

FLUIDTHERM TECHNOLOGY CHINA’S CEMENTED CARBIDE INDUSTRY HAGEN SYMPOSIUM 2015

Published by Inovar Communications Ltd ipmd.net PowderMetallurgyReview FALL2015.pdf 1 8/19/15 11:26 AM

FACILITIES

PEOPLE PRODUCTS IMAGINATION DRIVES INNOVATION THE FUTURE OF PM SOLUTIONS HAS ARRIVED!

The potential of powder metallurgy is only limited by one’s imagination… Hoeganaes Corporation, the world’s leader in the production of metal powders, has been the driving force behind the growth in the Powder Metallurgy industry for over 65 years. Hoeganaes has fueled that growth with successive waves of technology which have expanded the use of metal powders for a wide variety of applications. Hoeganaes Corporation Innovation Center The World Class in Cinnaminson, NJ, USA. The site houses the Research and Development facilities Engineers and for advanced engineered powders, such as AncorTech™ PM products and AncorAM™ Scientists at powders for Additive Manufacturing. Hoeganaes’ new Innovation Center develop the new products and processes that move the state of the industry forward, spanning Automotive applications to Additive Manufacturing. Our AncorTech products o er customers more ecient PM solutions with enhanced dynamic properties, higher densities, and greater design freedom. With melting, atomizing and mixing facilities in North America, Europe, and Asia, Hoeganaes serves our customers across the globe with the most advanced PM solutions.

Editor & Publishing Director Paul Whittaker REVIEW Tel: +44 (0)1743 454992 Email: [email protected]

Managing Director Nick Williams Tel: +44 (0)1743 454991 Email: [email protected]

Consulting Editor Dr David Whittaker Consultant, Wolverhampton, UK

Production Hugo Ribeiro, Production Manager India’s Powder Metallurgy Tel: +44 (0)1743 454990 Email: [email protected] industry continues to thrive

Accuracy of contents India is one of the world’s fastest growing major economies Whilst every effort has been made to ensure the accuracy of the information in this publication, and with a reported GDP growth of around 7% a year the the publisher accepts no responsibility for country has been one of the few to defy global economic errors or omissions or for any consequences slowdowns. There is increasing demand for vehicles and arising there from. Inovar Communications Ltd cannot be held responsible for views or claims luxury goods, a fact not lost on many businesses that expressed by contributors or advertisers, which see opportunities in the huge domestic market, as well are not necessarily those of the publisher. as making use of a large, relatively low cost workforce to Reproduction, storage and usage manufacture those goods. Single photocopies of articles may be made for personal use in accordance with national The global automotive industry is no exception and is copyright laws. Permission of the publisher and payment of fees may be required for all other investing in India, with many of the major automotive photocopying. manufacturers now having bases in the country. Increased All rights reserved. Except as outlined above, automotive production of course leads to growth in the supply no part of this publication may be reproduced, chain, which is reflected in the growth of India’s Powder stored in a retrieval system, or transmitted in any form or by any means, electronic, Metallurgy industry. photocopying or otherwise, without prior permission of the publisher and copyright owner. There are however still a number of challenges for the Submitting news and articles country to overcome. As our interview with the President We welcome contributions from both industry of the Powder Metallurgy Association of India reveals, the and academia and are always interested to hear region’s improving infrastructure is seen as one of the main about company news, innovative applications for PM, technology developments, research and factors enabling further growth in the manufacturing sector. more. Please contact Paul Whittaker, Editor Remaining in Asia, China is the world’s leading producer of Tel: +44 (0)1743 454992 cemented carbides accounting for over 40% of an estimated Email: [email protected] global production of 65,000 mt in 2014. The President of the Subscriptions Cemented Carbide Branch of the China Tungsten Industry Powder Metallurgy Review is published on a Association reports on the current status, challenges and quarterly basis. It is available as a free electronic manufacturing outlook for the cemented carbide industry in publication or as a paid print subscription. The annual subscription charge is £85.00 including China to 2020. shipping.

Advertising opportunities Paul Whittaker Contact Jon Craxford, Advertising Director, to Editor, Powder Metallurgy Review discuss how we can help promote your products and brand, both online and in print. Tel: +44 (0) 207 1939 749 Fax: +44 (0) 1743 469 909 Email: [email protected]

Design and production Inovar Communications Ltd.

ISSN 2050-9693 (Print edition) Cover image ISSN 2050-9707 (Online edition) Powder Metallurgy sintering © 2016 Inovar Communications Ltd. furnace (Courtesy Fluidtherm Technology) ipmd.net© 2016 Inovar Communications Ltd Spring 2016 Powder Metallurgy Review 1 Worldwide Global manufacturer of nodular and spherical aluminum powders, pre-alloyed aluminum powders, and aluminum premixes for PM www.ampal-inc.com www.poudres-hermillon.com

In the Americas Supplier of carbonyl iron and atomized stainless steel powders for the PM and MIM industries

United States Metal Powders, Incorporated 408 U.S. Highway 202, Flemington, New Jersey 08822 USA Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 email: [email protected]

USM 2013 PM Review and PIMI.indd 2 16/01/2013 10:41:40 Spring 2016 POWDER METALLURGY REVIEW

7 36 45 49 60

in this issue

33 INDIA FOCUS: The challenges and outlook 59 Hagen 2015: Advances in metal powder for India’s Powder Metallurgy industry technologies at Germany’s annual PM During a visit to India on behalf of Powder symposium Metallurgy Review, Dr Georg Schlieper took The Hagen Symposium, organised by the opportunity to meet with the President of Germany’s Fachverband Pulvermetallurgie, is Powder Metallurgy Association of India. During the annual meeting for the German speaking the meeting questions were answered regarding PM community. We report on a number of the the current state of India’s PM industry and the key presentations from this year’s event. opportunities for growth in the country. 67 Safety in the PM industry: Steps in 39 INDIA FOCUS: Fluidtherm Technology, reducing the risk of fire and explosion India’s innovative furnace manufacturer with metal powder dusts looks forward to continued growth A session on combustible dusts at last Fluidtherm Technology Pvt Ltd is India’s largest year’s POWDERMET2015 conference held in manufacturer of furnaces for the Powder San Diego, USA, included two papers which Metallurgy industry. Dr Georg Schlieper reports assessed the potential risks with metal dusts on a recent visit to Fluidtherm where he met with and, perhaps more importantly, provided the company’s founder and CEO, Narasimhan guidance on mitigation strategies to avoid Gopinath. these risks. Dr David Whittaker reports for Powder Metallurgy Review on the papers from Worldwide 49 China’s cemented carbide industry: this session. Global manufacturer of nodular and spherical aluminum powders, Growth prospects for the world’s leading pre-alloyed aluminum powders, and aluminum premixes for PM producer www.ampal-inc.com www.poudres-hermillon.com China is the leading global manufacturer of regular features cemented carbides with over 40% market share. In the Americas Zhongjian Zhang, President of the Cemented Supplier of carbonyl iron and atomized stainless steel powders for Carbide Branch of the China Tungsten Industry 4 Industry news the PM and MIM industries Association, identifies key players and reports on 72 Advertisers’ index the current state and outlook for the cemented United States Metal Powders, Incorporated carbide industry in China. 72 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] © 2016 Inovar Communications Ltd Spring 2016 Powder Metallurgy Review 3

GKN Powder Metallurgy reports record year for powder sales

GKN plc has reported its results GKN Powder Metallurgy for the year ended 31 December GKN Powder Metallurgy, comprising 2015, showing sales for the whole GKN Sinter Metals and Hoeganaes, group increased to £7,689 million. reported 2015 sales of £906 million Operating profit fell slightly to £679 with a trading profit of £109 million Around 80% of GKN Powder Metal- million (-1%) over the previous year. (up 6% on previous year). The lurgy sales are to the automotive “GKN continued to make company announced record sales market. The Ford F-Series trucks progress in 2015 and delivered on of powder for the year. Underlying are using GKN forged PM gears in our expectations. We performed sales growth was achieved in North open differentials and transmissions well against our key markets, America, China and Europe but sales (Courtesy GKN) overcoming some demand in Brazil fell sharply due to weaker weakness and demonstrating automotive and industrial markets. • Its position in China being once again the strength of our The divisional trading margin was further enhanced by forming a businesses, strong market positions 12.0% (2014: 11.0%), reflecting the new venture to produce metal and leading technology,” stated move towards higher value “design powders, subject to approvals Nigel Stein, GKN’s Chief Executive. for Powder Metallurgy” parts and a • Development of new technically “Highlights of the year were small margin benefit from lower raw enhanced powders continuing GKN Aerospace’s acquisition material prices passed through to with a new research titanium of Fokker Technologies, strong customers. atomiser being commissioned market-beating growth by GKN During the year, GKN stated at the Powder Innovation Centre, Driveline and good margin advances that its Powder Metallurgy division in the USA and the attainment by GKN Powder Metallurgy. Looking achieved a number of important of AS9100 Certification for the forward, we expect 2016 to be a milestones, which included: AncorTi™ range of gas atomised year of good growth, helped by the • Winning around £185 million titanium powders for aerospace contribution from Fokker,” added of annualised sales in new and applications. Stein. replacement business www.gkn.com

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Metalvalue and Asco Industries to Powder Metallurgy construct world’s largest gas atomised gearbox on show metal powder plant Höganäs AB, Sweden, has reported that there was great interest shown France’s Metalvalue SAS and Asco- Powder Metallurgy process. The in Powder Metallurgy gear technology Industries have set up a joint venture Scanpac® MMS process has already at last year’s CTI International Trans- forming Metalvalue Powder, to been licensed to a number of compa- mission Symposium and Expo, Berlin, produce gas atomised metal powders nies and the new atomising plant December 8-10, 2015. The world’s in what they claim will result in will supply metal powders to these first six-speed manual transmission A Global Leader in Water & the building of the world’s largest clients, as well as supplying those demonstrator car equipped with PM gas atomising plant. Studies are using current PM processes. gear technology was on display. Gas Atomized Metal Powders underway to finalise the location of Metalvalue also announced it is The CTI Symposium and Trans- the site. establishing a parts manufacturing mission Expo is the largest transmis- & HDH Based Titanium Powders Following the acquisition of plant in Etain, Meuse, France, that sion event in the world. The show Swedish company Bofors Bruk, will initially double the production attracts participants from all of the For Press & Sinter, Metal Injection Molding and parent company of Metec/Hydro- capacity of the Bofors Bruk facility in major automobile and transmission pulsor, Metalvalue acquired patents Sweden. Spray Coating applications ranging from Aerospace manufacturers, as well as suppliers relating to the Scanpac® MMS www.metalvalue.fr to Automotive, and Tool Steels to Medical Products, from all over the world. Höganäs exhibited as part of the Powder depend on AMETEK Specialty Metal Products. Our Metal Gearbox Initiative, the unique ability to provide custom powders that meet your PM industry collaboration to prove Numanova Srl to manufacture the concept, potential benefits and exact specifications makes us your ideal supplier. implementation readiness of PM range of powders for PM and AM gear technology in modern automotive transmissions. “We made a lot Whether you need large or small batches, our applications of new connections into the automotive industry and the transmission proprietary manufacturing methods allow us to meet Italian investment group Italeaf “The production of metal engineering expert community,” has announced it has established powders and the research and the most demanding and comprehensive specifications. stated Eckart Schneider, Director Numanova Srl to produce metal development activity to make new Global Development PM Components powders suited to a range of Additive alloys are attracting interest and at Höganäs. If you’re looking for metal powders that support Manufacturing and Powder Metal- growing expectations on the global The final conference day included lurgy applications. The production market,” stated Paolo Folgarait, your capabilities, help you develop new applications a test drive at a race track. There plant will be located at Italeaf’s Numanova’s Executive Director and were some 15 different vehicles or markets, and enable you to meet your customers’ facility in Nera Montoro, near Rome, General Manager. ranging from Porsches to Opels and the company plans to have oper- “The versatility of the techniques unique requirements, there’s only one name you available. The consortium’s demon- ating offices in Milan, London and of Powder Metallurgy can help strator vehicle was one of the cars need to know. Hong Kong. to create complex and innovative and demonstrated the performance Numanova states it will be active metallic materials (and ceramic) of the PM gears. “Everything went in the production of high-quality and introduce new forms of produc- well,” added Anders Flodin, PMC metal powders for Additive Manufac- tion in advanced sectors with high Höganäs. “The drivers could not turing (3D printing), Metal Injection added value,” added Folgarait notice that there was any difference Moulding (MIM) and Hot Isostatic Numanova added that it has between a regular transmission and Pressing (HIP). The metal powders concluded a number of framework a PM geared transmission, which will be suited to advanced uses in agreements for business collabo- is what the Höganäs led PM gear areas such as aerospace, energy, ration and technical-scientific consortium wanted to achieve.” mechanical and biomedical. cooperation with metal Additive Innovative & Advanced Metallurgical Technology www.hoganas.com Investment of some €12 million Manufacturing systems providers 1085 Route 519 has been announced and the and companies operating in the Eighty Four, PA 15330 USA company will be equipped with metallurgical sector. It has also Tel: +1 724-250-5182 • Fax: +1 724-225-6622 advanced gas atomised metal signed agreements with national Email: [email protected] powder production technology. It and international universities and will also use plasma atomisation research centres. www.ametekmetals.com technologies and total production www.italeaf.com capacity is expected to be around 500 tons/year of metal powders.

Makin Metal Powders appoints new Abbott Furnace Managing Director and expands team announces Makin Metal Powders, based in company GRIPM. Yan will retain departure of its Rochdale, UK, has announced that responsibility for East Asia Sales. President Jonathan Hood has been appointed In February 2016 Steve Ellis Managing Director following the was appointed as the new Sales Abbott Furnace Company, based retirement of Dr John Boden on and Technical Director. Ellis has a in St. Mary’s, Pennsylvania, USA, January 1st 2016. degree in materials science as well has announced that Jose M Medina Hood, whose previous role was as experience in metal powders and has tendered his resignation as that of Sales and Technical Director will represent a significant boost President, effective February 5, for the company, is a highly quali- to the technical expertise available 2016. Abbott Furnace added that its fied metallurgist and is said to have at Makin. Ellis has also operated Directors will take over responsibility a clear idea of how the company can at senior levels with companies in for the day to day running. continue to grow and develop under manufacturing and copper metals “We are thankful for Mr Medina’s his leadership over the next decade.® and will bring great operational and leadership over the past year as KeystoneIt was announced that as a first Powderedstep customer service knowledge Metal and the company CompanyCompany has undergone a he is expanding the leadership team expertise to his new role. successful transition in ownership. by adding two new faces to the board. Other changes announced We appreciate the support he has On January 4th, Michael Yan, include the appointment of Phil given to our employees and wish him who was previously responsible for Wilcock as Finance Director after success as he moves forward,” the sales in East Asia, joined the board the retirement of Brian Hope in company stated. as Marketing Director. Yan has a October 2015. Wilcock was previ- Abbott Furnace manufactures a technical background as well as ously Makin’s Management range of industrial furnaces for a considerable experience in Marketing Accountant. number of applications. and Sales for both Makin and parent www.makin-metals.com www.abbottfurnace.com

Raising the potentialRaising for the powdered potential metal for applications powdered

metal applicationsMPIF 2015 MPIF 2014 Driven by GRAND GRAND PRIZE PRIZE innovative thinking, AWARD AWARD KeystoneDriven hasby innovativea solid thinking, Keystone has a solid reputation forreputation bringing industryfor bringing industry firsts to market. firsts to market. Join us in pioneering the next leap forward for Join us in pioneering powdered metal manufacturing. the next leap forward for powdered metal manufacturing. Keystone Powdered Metal Company 251 State Street St. Marys, PA 15857-1697 Phone 814-781-1591 www.keystonepm.com Email: [email protected] Keystone Powdered Metal Company | 251 State Street | St. Marys, PA 15857-1697 | Phone 814-781-1591 Email: [email protected]

8 Powder Metallurgy Review Spring 2016 © 2016 Inovar Communications Ltd ELNIK takes the gamble out of ELNIK takes the gamble out of ELNIKbuyingELNIK takes takesMIM debindthethe gamblegamble and sinter out ofof buying MIM debind and sinter buyingequipmentbuying MIM MIM with debinddebind the helpandand sinterof equipment with the help of equipmentDSHequipment Technologies! withwith thethe helphelp of DSH Technologies! Elnik provides FREE TRIAL RUNSDSHDSH BEFORE Technologies! Technologies! YOU PURCHASE OUR EQUIPMENT Elnik providesto FREE prove TRIAL how cost-efficientRUNS BEFORE our YOU technology PURCHASE can beOUR EQUIPMENT ElnikElnik provides provides toFREE FREEprove TRIAL TRIAL how RUNS cost-efficientRUNSELNIK BEFORE BEFORE takes YOU ourYOU technologyPURCHASE PURCHASEthe gamble can OUROUR be EQUIPMENT out of Wasted MIM production runs resulting in “half-baked” parts can cost you thousands $$! 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Elnik Spring 2016.indd 1 08/03/2016 12:14:24

year’s level. The reported net income SHW AG on target as Powder for the year was €14.4 million, an Metallurgy sales increase 8% increase of 34% on the previous year’s figure of €10.7 million. Germany’s SHW AG, a leading Due to the lasting high level of Efficiency programmes in Powder automotive supplier of automo- customer call-offs, particularly in Metallurgy and pump assembly deliv- tive pumps, engine components the Pumps and Engine Compo- ered initial successes and brake discs, has published its nents business segment, in the The Pumps and Engine Compo- preliminary, unaudited key perfor- fiscal year 2015, SHW stated that nents business segment recorded mance indicators for the fiscal year it was once again able to discon- an increase in sales of 9% to 2015. nect itself from the general market €365.2 million in the fiscal year 2015 “We achieved major progress in trend and boost its group sales by (previous year: €333.6 million). Sales the final stage of the fiscal year,” 8% to €463.5 million (previous year: in its Passenger Car division grew stated Dr Frank Boshoff, Chief €430.0 million). Incoming orders by 13% to €306.6 million (previous Executive Officer of SHW. “We at the group’s domestic companies year: €272.0 million) due to strong reduced the tailbacks further in the totalled €445.0 million, almost customer demand for variable oil/ Powder Metallurgy at our Aalen- reaching the previous year’s record vacuum pumps, electrical auxiliary Wasseralfingen plant and in the amount of €453.5 million. pumps for the start-stop function pump assembly at our Bad Schus- Adjusted consolidated earnings and camshaft phasers. The Industry senried plant. I am positive that before interest, taxes, depreciation division contributed €27.7 million to the measures to enhance capacity and amortisation (adjusted EBITDA) sales (previous year: €29.8 million). at our Aalen-Wasseralfingen plant improved by 7% from €40.6 million The Powder Metallurgy division will be implemented by the end of to €43.5 million and was there- boosted its total sales (including the first quarter 2016 as scheduled, fore within the target range of €42 internal sales) in the fiscal year thereby sustainably enhancing our million to €46 million publicised 2015 by 8% from €53.1 million to profitability in the Pumps and Engine last September. The corresponding €57.5 million. Components business segment.” margin of 9.4% was at the previous www.shw.de

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factory tour. Topics to be covered LPW commences EPMA PM Summer include the manufacture of metal Plasma School 2016 powders, MIM, modelling, sintering, HIP, magnetic materials and AM. Spheroidisation of The European Powder Metallurgy The Summer School is designed metal powders Association (EPMA) has announced for young graduate designers, engi- that its 2016 PM Summer School neers and scientists from disciplines will take place in Valencia, Spain, such as materials science, design, from June 27 to July 1, 2016. The engineering, manufacturing or five-day residential training course metallurgy. Graduates under 35 and will be a mix of lectures, given by who have obtained their degree from experts drawn from both industry and a European institution are eligible to academia, laboratory work, group apply. discussion, problem solving and a www.epma.com

LPW Technology has announced that its Plasma Spheroidisation equipment is now operational and producing metal powders for use in the Additive Manufacturing industry. The process uses high energy plasma to produce cleaner, highly spherical and dense metallic powders with greater flowability, reducing down time on the machine and speeding up the manufacturing process. “We are hugely excited to have PM China 2016 this next generation equipment Shanghai on site for the benefit of our customers. LPW are constantly 27-29 April 2016 reacting to solve our customer’s problems and ensure that we have the right solution to keep them on track,” stated Mike Ford, LPW’s Sales Director. “Our Plasma Spheroidisation can produce the best metal powders on the market. They are more spherical and cleaner than those currently available.” The most significant benefit of this novel technology is perfectly PM Tooling System spherical powder with no satellites, which increases the flowability The EROWA PM tooling system is the standard and packing density of the powder, interface of the press tools between the especially on AM machines where finer powder is required. In addition, toolshop and the powder press machine. levels of surface contamination, Its unrivalled resetting time also enables compared to conventional gas-atomised powders, are you to produce small series profitably. reduced. This has the potential to enhance mechanical properties in www.erowa.com the finished AM component. www.lpwtechnology.com

China aims to complete restructure of EPMA launches its rare earth industry by mid-2016 2016 PM Thesis The Chinese government has Information Technology, is reported Competition announced that its plans to to have said that consolidation is restructure the country’s rare earth already underway. “To deal with The European Powder Metallurgy mining industry will be completed by current problems in China’s rare Association has announced the summer 2016. As the world’s largest earth industry, we are consolidating launch of its 2016 Powder Metallurgy producer and exporter of rare-earths, and upgrading the industry in terms Thesis Competition at both Diploma China has had a number of problems of production and mining procedures. (Masters) and Doctorate (PhD) managing its resources. Companies So far, three firms have already levels. The aim of the competition flooding the market have led to over- formed rare-earth blocs, while is to develop an interest in Powder capacity, which is blamed for falling another three are still working on it.” Metallurgy, including Metal Injection prices, and there have been issues Xin Guobin stated that it is the Moulding, among young scientists at with illegal mining and smuggling. government’s hope this will be European academic establishments, “But beyond excess capacity, completed by the summer. “By and to encourage research at under- illegal mining and illegal production the end of June we must complete graduate and post-graduate levels. also have a huge impact on the the consolidation of all rare earth The competition is open to all industry. Certain raw ores are illegally mines and firms in China. While applicants who have graduated from dumped by individuals as recyclable this happens, we will continue to a European university and who have materials, then later extracted. This work with the companies through had their theses approved during the has formed an illegal industry chain our various ministries to support 2013/2014, 2014/2015 or 2015/2016 which has a very bad influence on the newly formed rare earth blocs, academic years. the development of China’s rare especially those who finish their The prizes, sponsored by Höganäs earth industry. So, we need to crack consolidation on time. “ AB, will be presented at the World down on that,” Chen Zhanheng, Vice The Ministry of Industry and PM2016 Congress & Exhibition, Secretary General of China’s Rare Information Technology has stated which will take place October 9 - 13, Earth Industry Association, is reported that it expects there will be a in Hamburg, Germany. The winner by news service CRI as saying. reduction of rare-earth smelting of the diploma category will receive In 2014, the Chinese government this year through improved a cheque for €750 and the doctorate singled out six different rare-earth output controls and increased category winner will receive €1,000. industry leaders, promising them competitiveness. It was also reported Both winners will also receive free support to create large rare-earth that Chinese authorities stated that registration to the World PM2016 producers by buying up small scale the country’s rare-earth industry will Congress. operations. have the world’s best technology in The deadline for submitting At a recent meeting, Xin Guobin, use by the end of 2020. entries to the competition is April 29. China’s Vice-Minister of Industry and www.epma.com

Porvair expands range of sintered steam filters

Porvair Filtration Group, based in filter elements are stated as having Fareham, UK, has launched a new exceptional dirt-holding capacity and range of steam filters for process and are designed to withstand demanding culinary applications. Its Sinterflo® temperature and pressure conditions. stainless steel filter elements are “Quality is at the heart of every customers,” stated Porvair’s Market available in high quality 316L sintered stage of our operation and a Manager, Andy Fairlie. metal fibre, metal mesh and sintered fundamental part of our culture. Porvair’s steam filters are metal powder media. Our continuous innovation in steam available in a selection of grades Porvair’s process steam filters filtration products enables us to for the bespoke requirements are used where clean, dry steam is offer new and better solutions to across applications such as sterile critical for plant performance and applications - and our widened range packaging, pharmaceuticals, continuous operation, but where for production processes is pivotal brewing, dairy farming, food and there is no direct contact with the to that strategy. It’s all in the pursuit beverage and chemical production. manufactured product. The steam of the best possible solutions for our www.porvairfiltration.com

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EPMA announces new ALD Vacuum Technologies Executive Director expands market presence The European Powder Metal- in North America with lurgy Association (EPMA) has announced that Dr Lionel acquisition of ALD-Holcroft Aboussouan is to be appointed AMG Advanced Metallurgical Group N.V. has announced as EPMA Executive Director, that ALD Vacuum Technologies of Hanau, Germany, has succeeding Jonathan Wroe who acquired the remaining 50% share of its joint venture died suddenly late last year company ALD-Holcroft Co. Inc. of Wixom, Michigan, USA following a short illness. from AFC-Holcroft LLC of Wixom, Michigan, USA. Aboussouan will officially ALD-Holcroft, formed in 2005, acts as the exclusive begin the day-to-day running sales agent for ALD’s heat treatment product lines in of the EPMA, its staff and the NAFTA region. It was stated that the acquisition will projects, following the associa- enable AMG to streamline its heat treatment and metal- tion’s General Assembly on April 8, 2016 in Brussels. In lurgy furnace marketing operations in North America, the meantime, Dr Volker Arnhold, former GKN Executive Canada and Mexico. AMG produces highly engineered Manager and EPMA Board & Council Member, has been specialty metals and mineral products and provides recruited as a temporary Executive Director to assist related vacuum furnace systems and services. during Aboussouan’s introductory period. AMG Critical Materials produces aluminium master Aboussouan has previously worked at Arcelor Research alloys and powders, titanium alloys and coatings, ferro- and the World Steel Association, which represents over 150 vanadium, natural graphite, chromium metal, antimony, steel producers (including nine of the world’s ten largest tantalum, niobium and silicon metal. AMG Engineering steel companies), national and regional steel industry designs and produces vacuum furnace equipment and associations and steel research institutes. systems used to produce and upgrade specialty metals More recently Aboussouan was employed at Arcelor- and alloys for numerous markets. Mittal as the Head of Health, Safety, Environment and www.amg-nv.com Quality, for one of the company’s business units. “Many of Lionel’s skills and working practices that he has gained over his working career will be a real asset to the EPMA moving forward,” stated EPMA President Phil- lippe Gundermann. “Lionel will build on the firm founda- tions left by Jonathan and work with EPMA Members, staff and stakeholders to continue the success of one of Europe’s leading trade associations.” www.epma.com

Carpenter to add titanium furnace equipment to its new superalloy powder facility

Carpenter Technology Corporation, Wyomissing, Penn- sylvania, USA, is reported to be spending an additional $23 million to add titanium furnace equipment to its new superalloy powder facility in Limestone County, Alabama. The purchase will raise Carpenter’s investment in the plant to $61 million. The new plant’s titanium powder product offering will Suppliers of metal powders to the PM Industry increase Carpenter’s reach into aerospace and medical since 1945 markets and offer growth opportunities in transportation, Tony R. Thene, Carpenter President, CEO and Director told the Decatur Daily. Carpenter is close to completing its Ronald Britton Ltd, second Limestone County plant. The company’s first Lime- Regent Mill, Regent Street, Rochdale, United Kingdom stone County plant, a $518 million superalloy metal plant, Tel: +44 (0)1706 666 620 Cert No. 9125 ISOCert. 9001, No. ISO 9125 14001 began production in early 2014. web: www.ronaldbritton.co.uk ISO 9001 ISO 14001 www.cartech.com

stated CEO Dr Markus Rechlin. SLM Solutions to begin metal “We are planning a total production powder production capacity of more than 100 tonnes of aluminium powder per year for SLM Solutions Group AG, a in the consumables area. Together Additive Manufacturing purposes. provider of metal-based additive with TLS’s main shareholder, we We aim to offer other materials than manufacturing systems based in will invest a mid-range, single-digit aluminium at a later point in time.” Luebeck, Germany, has announced it million euro amount to this end.” SLM Solutions intends to bundle is entering into a cooperation venture The development, production and the powder business within a with PKM Future Holding GmbH to distribution of aluminium alloys for separate organisational unit, together manufacture metal powders. PKM is metal-based Additive Manufacturing with further services for the AM of the main shareholder of TLS Technik systems is intended to form the metal components such as training, GmbH & Co Spezialpulver KG, a core of the cooperation between consulting and financing, in order manufacturer of gas atomised metal PKM Future Holding GmbH and to take the particularities of the powders in Bitterfeld, Germany. SLM Solutions Group AG, within a business into account. “At the time of our IPO we had joint venture that will be formed. “By generating continuous clearly stated our three-column According to the contract, SLM sales over the course of the year, growth strategy: alongside research Solutions intends to acquire 51% of expanding the powder business and development, as well as the share capital of this planned joint should help us offset the strong distribution and service, the planned venture. seasonality of our system business,” expansion of our metallic powder “We are starting off with added Bögershausen. “Over and business was to represent a decisive aluminium, an important material for beyond this, the consumables area building block,” stated SLM Solutions’ us, and we are planning – along with is also interesting for us due to the CFO Uwe Bögershausen “We are actual production – to also implement fact that attractive margins can be pleased to have now found the right refining steps for the powder. This will achieved through developing and partner in PKM, enabling us to offer enable us to adapt consumables even marketing metallic powders.” our customers tailored solutions better to customer requirements,” www.slm-solutions.com

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Performance Ingredients Functional Chemicals Hoeganaes Corporation announces AS9100C Certification Metal Powder Lubricants

Hoeganaes Corporation, based in Cinnaminson, New Jersey, USA, has announced that it has achieved AS9100C Quality Management System certification for its Innova- tion Center facility located in Cinnaminson. The AS9100C Quality Management System provides the basic quality framework necessary to address both civil and military aviation and aerospace needs. This enhancement to Hoeganaes’s quality systems follows a multimillion-dollar investment in 2015 for the commercialisation of advanced powders for Addi- tive Manufacturing and MIM. The production, design and distribution of its AncorTi™ range of gas atomised titanium powders are now certified under the scope of this rigorous aerospace quality standard. “The attainment of AS9100C certification further demonstrates our long term commitment to delivering high performance powders for AM to world class customers operating in aerospace markets,” stated Mike Marucci, Global VP, Advanced Technology. Hoeganaes continues to be certified under the ISO/TS 16949 for automotive quality management, ISO 14001 environmental management and OHSAS 18001 safety management systems. www.hoeganaes.com Acrawax® C Lubricant

Titanium Europe 2016 event Setting the standard in the metal powder industry, Acrawax® heads to Paris C Lubricant is a clean-burning, metal free lubricant that does not generate metallic or corrosive byproducts. Acrawax® The International Titanium Association has announced C Lubricant is combustible, leaving no residue on sintered that its Titanium Europe 2016 conference and exhibition parts. will take place in Paris, France, April 18 – 20. The event will provide a platform to gain insights into the European titanium industry and will serve as a networking venue for Acrawax® C Lubricant Offers: business executives and consumers alike. Presenters at the conference will provide outlooks on – Precise particle size control world supply and demand, look at developments in the – Free flowing powder mixes ever-lengthening global supply chain, clarify business – Low die wear and easy part removal from the die trends driving the key commercial aerospace sector – Reduced part distortion and report on the dynamics of the titanium industry in developing new industrial markets and development of – Variety of custom particle sizes innovative products. They will also share insights on the potential for titanium Additive Manufacturing as a novel, game-changing technology. The event is anticipated to draw a strong number of industry professionals to discuss the dynamics of the European titanium industry. The organiser is also planning a variety of industry related and sightseeing tours for delegates, which includes a visit to Snecma, one of the world’s leading manufacturers of aircraft and Contact us to learn more: E: [email protected] rocket engines. T: + 1 201 316 9200 www.lonza.com www.titanium.org

4.2 million units with the increase in VAT said to be the main Solid global growth in reason for the decline. Passenger car production in Japan auto sales and production was down by 5.5% in 2015 to 7.830 million compared with a year earlier. Car production in South Korea increased by expected to continue in 2016 1.2% to 4.58 million, which is just short of the peak of 4.66 million achieved in 2011. Korean car sales increased by 9.1% 2015 was a good year for the global automotive to 1.81 million. industry. In Western Europe (EU28+EFTA) 2015 showed Other significant car markets in the ASEAN region include an increase in new car registrations of 9.2% to 14.2 Thailand and Indonesia. Thailand reported a 1.76% increase million units with the smaller Western European car in vehicle production in 2015 to 1.913 million but a 9.4% drop markets such as Netherlands, Sweden, Belgium and in sales to 799,632 units. Vehicle production in Indonesia Denmark showing particularly good gains. The Russian dropped by 15.4% in 2015 to 1.098 million. light vehicle market, however, is still contracting with India has one of the largest vehicle manufacturing indus- sales falling by 36% to 1.6 million units, a level last tries in the world with annual production of 23.37 million seen during the crisis of 2009. units reported for financial year 2014/2015, an increase of The US market for new light vehicles sales grew 8.7% over the previous year. Of this total, car production by 6% in 2015 to 17.4 million units whilst light vehicle accounted for 3.220 million units, a growth of around 6%. In production in the USA saw a 3.6% increase to 11.77 Brazil new vehicle registrations dropped by 26% in 2015 million units. Overall light vehicle production in North to less than 2.5 million as the country continues to battle America increased by 3% in 2015 to 17.95 million units with a deep recession. Vehicle output in South America was with Mexico up 6.1% to 3.39 million units but Canada’s down an estimated 20% for the region as a whole and with production contracted by 4.8% to 2.27 million. Brazil down by 22%. Further declines are expected in South The Chinese passenger car market continues to America in 2016. break records with sales climbing by 7.3% in 2015 to Forecasts from IHS Automotive, a leading source of 21.146 million units and production rising by 5.8% to market data on the global automotive industry, predict that 21.079 million. Sales were particularly strong in the China, Europe and North America will again do well in 2016. smaller engine cars (up to 1.6 litres) for which tax Europe is forecast to grow by around 1.7% with production breaks were introduced in October. surpassing 21 million units. China is likely to achieve over 5% In Japan new car sales slumped by 10% in 2015 to growth in output in 2016, whilst Japan is expected to achieve a more modest growth of 2.3%. India’s automotive sector is forecast to grow by around 9% in 2016. PRECISION

PERFORMANCE Engineering Materials Bodycote charts the history PRODUCTIVITY of metallurgy with interactive PRICE timeline Bodycote, UK, has added an Interactive History of Metal- lurgy to its website that charts the history of metal In other words: tight Dimensional Control, high Mechanical processing and heat treatment. Containing over 200 images Performance, fast and consistent Flowability, Cost Competitiveness and numerous videos, the timeline identifies important and versus other materials and manufacturing technologies. We at IMERYS Graphite and Carbon address the 4 P’s of Powder fascinating discoveries in the working of metal during more Metallurgy and Hard Metals by presenting tailor made offerings to the Market. Our portfolio of Carbon Solutions consists of High than 10,000 years of history. Purity Synthetic Graphite, Highly Conductive Carbon Black and Starting in 8700BC with the world’s oldest known copper Natural Flake Graphite (processed from our 100% owned Canadian mine, located in Lac-des-Îles, Quebec). We remain committed artefacts, through to the metallurgy and engineering to the key characteristics of Purity and Oversize Control. processes of today, the resource charts the development of metal working from early mankind through to the scientific and technical breakthroughs of the 20th century. Bodycote developed the interactive resource to explore the evolution of metallurgy and heat treating and to acknowledge the collective work of scientists and engineers whose hard work and discoveries have enhanced the properties of metals and alloys making them better suited to deliver safer, more durable results in an expanding field of applications. www.bodycote.com/history-of-metal

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Anhui Yingliu Group installs Quintus PIM International Hot Isostatic Press out now

Jan Söderström, CEO of Quintus The 88 page March Technologies (formerly Avure Tech- 2016 issue of nologies), joined Frank Du, President Powder Injection of China’s Yingliu Group, to celebrate Moulding Interna- the inauguration of a Quintus® Hot tional (Vol. 10 No. Isostatic Press (HIP) at the Anhui 1) has just been Yingliu Group Huoshan Casting Co. published and is now Ltd. foundry in Anhui province, China, available for free in early December 2015. PDF download from the magazine’s The new HIP is the world’s largest istics that are difficult to achieve in website. In addition to over 40 pages in its pressure and temperature class. traditional manufacturing technology. of industry news, this issue includes The new press, QIH 1.6 x 2.5 – 2000 – “Quintus HIP systems produce the following articles: 1400M URC, brings several advanced parts with excellent isotropic mate- • Indo-MIM: A giant in Metal Injec- capabilities that enable the Huoshan rial properties and offer the highest tion Moulding expands to build facility to manufacture products possible density of all available on strong international growth meeting mission-critical performance compaction methods,” stated Jan • Opportunities in the PIM of standards in the aerospace and Söderström, CEO of Quintus Tech- Particulate Composites nuclear power environments. nologies. • Euro PM2015: Innovative mate- Operating at a pressure of The event was attended by more rials offer growth opportunities 200 MPA and temperatures up to than 500 guests, including repre- for PIM 1400°C, the Quintus HIP produces sentatives from prominent Chinese • High Pressure Capillary Rheom- complex components with improved companies in the aviation and nuclear eter, a simple way to measure fatigue strength and extended service power industries. the viscosity of MIM feedstocks? life, ever more important character- quintustechnologies.com www.pim-international.com

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Hardide Coatings opens new US facility

Hardide Coatings, headquartered support the increased demand from in Bicester, Oxfordshire, UK, has existing customers and significantly announced the opening of a new boost opportunities to expand provi- $7 million production facility in sion of our coatings throughout the Virginia, USA. The expansion has region. We have installed two large been driven by increased demand capacity chemical vapour deposi- from North American customers, tion (CVD) coating reactors and with sales to the US and Canada work is already progressing well on Jamey Ewing (left) and Barry Farmer more than doubling during 2015. The some very exciting customer trials. I of Hardide Coatings, Inc new factory is expected to create up would like thank all in Martinsville- to 29 jobs over the next three years. Henry County and Virginia Economic coating production processes and The site in Martinsville-Henry Development departments for their techniques and returned to Virginia County will service existing and help and assistance and in particular in September 2015 to assist with the new customers for the company’s Governor McAuliffe and Secretary installation and commissioning of patented range of hard wearing Jones for their personal support in the process, production and quality tungsten carbide coatings in the oil helping to get this project underway control equipment. and gas and flow control markets. in Martinsville.” “Production for North American In addition, the company also plans The first two senior employees customers, currently being carried to expand in the aerospace and at the facility, Jamey Ewing, Coat- out in the UK, will be gradually advanced engineering sectors and ings Supervisor, and Barry Farmer, transferred to Virginia on a case- develop applications for its newly- Pre-treatment Supervisor, spent 12 by-case and phased basis, taking patented coating for diamonds. weeks during the summer in the UK load and capacity of both sites into Philip Kirkham, CEO of Hardide at the company’s head office and consideration,”added Kirkham. plc stated, “Having a local produc- main production site in Bicester. The www.hardide.com tion facility in North America will pair were trained on the Hardide

Royal Metal Powders, Inc. located in Maryville, Tennessee, U.S.A. is a manufacturer of high-quality copper-based powders. Royal produces air and water atomized copper powders, offering a wide product range to serve the needs of its customers worldwide. Royal currently produces copper and copper based alloy products. Royal products include: copper, brass, bronze, bronze premix, infiltrating, copper/nickel, nickel/silver and copper phos powders. Applications include: powder metallurgy, MIM powders, friction, brazing, chemicals, water filtration, and numerous industrial applications. In addition to our main copper-based products we offer tin powders, electrolytic copper powders, and copper/tin powders. Royal has full R&D capabilities and offers a full technical service

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market was in oversupply leading Fall in metal prices to mine production of 87,000 mt Sandvik appoints continued in 2015 exceeding consumption in 2015. In new Executive VP late 2015 the sole tungsten mine Last year has seen a fall in the value in Canada suspended operations and CFO of a number of metals. Copper prices because of low W prices and was have more than halved since their placed on care and maintenance Sandvik has announced that Tomas peak in 2011, and dropped from status. Eight large Chinese tungsten Eliasson has been appointed $6300/mt at the beginning of 2015 to producers are reported to be Executive Vice President and CFO of around $4500/mt at end of January planning to reduce output of W Sandvik and member of the Group 2016. Nickel has fared even worse concentrates. Executive Management, effective no falling to $8500 from $15,500 a year Bucking this negative trend, later than July 2016. earlier, cobalt fell to $22,000/mt however, a new tungsten mine began Eliasson is currently CFO for from $31,000, and molybdenum from production in Zimbabwe in 2015; Electrolux, a position he has held $20,000 to $11,900/mt. Steel billet a large new mine in Vietnam has since 2012. Previously, he was CFO fell by more than 50% from $490/mt ramped up production for APT and for ASSA ABLOY during 2006-2012 to $220/mt. tungsten oxides, the Drakelands and Seco Tools between 2002-2006. Over the course of 2015 tungsten tungsten mine in Devon, UK, is His professional career started at (-40%), niobium (-21%) and tantalum scheduled to start production in ABB in 1987. (-37%) all experienced substantial August 2016 and new ferrotungsten “Tomas Eliasson has extensive downturns in both pricing and plants also began production in experience from relevant industries consumption and there is likely Russia and the Republic of Korea. and companies. He will be a strong to be a period of restructuring Drakelands is operated by Wolf contributor to Sandvik in the finance and consolidation of supply in the Minerals and said to have one of the areas and he will also take a leading year ahead. Tungsten APT prices Western World’s largest reserves of role in driving the further progress of continued their downward trend in tungsten at 37.5 million tonnes. Wolf the Sandvik Group in general,” stated the middle of 2015 to fall to $160- aims to generate 5,000 tonnes of Björn Rosengren, President and CEO $165 mtu in January 2016 from $320- tungsten concentrate per year over of Sandvik. $350 mtu a year earlier. The tungsten 10 to 15 years. www.sandvik.com

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Carpenter Technology relocating Metalysis receives corporate headquarters to Philadelphia £20 million

Carpenter Technology Corporation, a R Thene, Carpenter’s President investment producer and distributor of premium and Chief Executive Officer. “As we The Australian mining company, Iluka alloys, including special alloys, have expanded our manufacturing Resources Ltd, has announced that titanium alloys and powder metals, footprint and sales presence over it will invest a further £6 million in has announced plans to relocate its the past decade, it has become more UK metal powder producer Metalysis corporate headquarters to Philadel- important to raise our visibility, Ltd, with an undertaking to commit phia from Wyomissing, a suburb of broaden our talent pool and improve an additional £4 million before 15 Reading, Pennsylvania, USA. It was access to our customers and part- July 2016. The £10 million in total is stated that the new headquarters ners. The Reading manufacturing expected to take Iluka’s stake in the location will allow the company to location remains crucial to the company from 20.8% to 28.8%. deepen its customer relationships and current operating plan and the stated Iluka’s additional investment, play a more integral role in the devel- strategy going forward. We’re proud together with an investment of £10 opment of its customers’ products. of our 125 plus years in Reading, and million from UK based Woodford Carpenter anticipates that the new we remain committed to Reading and Patient Capital Trust will support Philadelphia location will ultimately be to the state of Pennsylvania, where Metalysis’ commercialisation process home to around 100 positions, while Carpenter today employs more than as it seeks to further develop its nearly 2,300 Carpenter personnel 3,300 personnel.” single stage process for a low cost, will remain in Reading. The company Carpenter is in the process of low environmental impact, transfor- added that no planned job reductions reviewing office locations in Phila- mation of various metals into powder are part of the relocation and the delphia appropriate to its needs and form. relocation is not expected to have any growth objectives, with the goal of David Robb, Iluka’s Managing material increase in overall expenses. completing the move in late 2016. Director stated, “If Metalysis can “Carpenter is positioning itself www.cartech.com commercially produce titanium for continued growth,” stated Tony metal powder direct from rutile and synthetic rutile, at materially lower cost than current technologies, then a dramatic expansion in demand for titanium metal and titanium alloys Kennametal appoints DeFeo as could be expected. The application President and Chief Executive Officer of titanium powder in 3D printing also presents potentially significant The board of directors of Kennametal appreciate Don opportunities in a rapidly expanding Inc. has announced the appointment Nolan’s service. market. Such developments would of Ronald M DeFeo as the company’s He was a neces- be positive for high grade titanium new President and Chief Executive sary change dioxide feedstock demand.” Officer (CEO). DeFeo replaces Donald agent through a Iluka’s support for Metalysis has Nolan, who has left the company period of signifi- been both financial and technical, to pursue other interests after cant turmoil and with an example of the latter aspect serving as President and CEO since uncertainty.” being test work involving the addition November 2014. A Kennam- of other elements to synthetic rutile “We have determined a change etal board member since 2001, DeFeo which allow customised titanium Our Cobalt Powder in leadership is necessary and are served as the Chairman of the Board metal alloys to be produced. pleased that Ron will step into this and Chief Executive Officer of Terex “Iluka is encouraged by the role,” stated Kennametal Chairman Corporation, a global manufacturer progress made by Metalysis towards Your Best Solution for of the Board of Directors Lawrence W of machinery and industrial products, commercialisation of its solid state Stranghoener. “Ron is a highly expe- from March 1998 and March 1995, metal powder technology. The rienced CEO who will bring much respectively, until his retirement from company is also pleased at the wisdom, experience and passion the company at the end of 2015. He increased focus on titanium as the for Kennametal. He will sharpen joined Terex in 1992. core element of the Metalysis stra- Cutting Costs and our focus, prioritise our results, “As a 14-year member of the tegic plan, with a goal to accelerate and motivate, engage and empower Kennametal board, I know what the commercialisation and licensing of our people to produce the finan- company and its people are capable its technology,” added Robb. Improving Performance cial results that are expected of an of achieving,” DeFeo stated. www.iluka.com industry leader like Kennametal. We www.kennametal.com www.metalysis.com Email: [email protected] 24 Powder Metallurgy Review Spring 2016 © 2016 Inovar Communications Ltd NANJING HANRUI COBALT CO., LTD. Visit us: www.hrcobalt.com Our Cobalt Powder Your Best Solution for Cutting Costs and Improving Performance

Herbert Danninger and Alberto Molinari receive

VACUUM FURNACES DESIGNED honorary doctorates from FOR HEAT TREATMENT POST Spain’s UC3M ADDITIVE MANUFACTURING Spain’s Universidad Carlos III de Madrid (UC3M) has STRESS RELIEVING, SOLUTION TREATMENT & awarded honorary AGING of ALLOYS PRONE TO OXIDATION doctorates to Nickel, Titanium, Cobalt-Chrome-Molybdenum, Tungsten Professor Herbert Danninger, TU EDIC TOM RON M A U OT E AU L A I A T Wien, Austria, and V I E C Professor Alberto S Molinari, University Shown left to right: Alberto Moli- of Trento, Italy. nari, Mónica Campos and Herbert The award is the Danninger during the presentation university’s highest VACUUM & CONTROLLED ATMOSPHERE TREATMENTS academic distinction and is given to an individual for their academic, scientific or artistic endeavours. for MATERIALS PRODUCED BY 3D PRINTING Both Danninger and Molinari are international experts • Specifically tailored to alloys prone to oxidation, in the field of materials science and engineering. “They are two exemplary figures in their field of knowledge,” stated • Perfect homogeneity thanks to our resistor’s Professor Mónica Campos during the ceremony. Campos patented design, is a professor in the UC3M Department of Materials Science and Engineering and Chemical Engineering. This • Clean treatment: molybdenum heating core and department and the Álvaro Alonso Barba Technological metal insulation, Institute of Chemistry and Materials promoted the • Optimum atmosphere controle during treatment investiture of the new doctors’ honoris causa. is optional: drew point probe and a mass In his acceptance speech, Danninger stated that it was a spectrometer, great honour to receive this degree from a university he has collaborated with for many years as a result of a shared • Increased productivity thanks to an accelerated interest in Powder Metallurgy. Professor Molinari, who neutral gas cooling (optional). also participated in joint research projects and teaching under the auspices of the Höganäs Chair, was deeply

Standard ed s n fi o moved by the new honorary doctorate award. In his speech, CONTACT : +33 4 76 49 65 60 ti r r m e e C AMS 2750 s he defended teaching and research as complementary AMS 2769 and basic paths at university. In addition, both mentioned the collaboration with UC3M Full Professor José Manuel Torralba, who was also attending the event as the regional government’s head of the Directorate General for Universities and Research. Both academics are linked to the prestigious Höganäs Chair in Powder Metallurgy, in which the UC3M participates. They have made many contributions through this association, such as participating in doctoral courses and other educational sessions, the exchange of doctoral students, the creation of joint science publications, etc. With more than 400 scientific publications in renowned journals, Danninger and Molinari have taught for more than a quarter of a century and held important posts at their universities. “Both have known how to maintain continuous relations with companies from the sector, allowing and facilitating an effective transmission of knowledge to companies,” added Campos. ECM TECHNOLOGIES - RCS GRENOBLE 478 969 173 N° Siret 000 44 Pictures Credit : Fotolia ECM TECHNOLOGIES WWW.ECM-FURNACES.COM www.uc3m.es

Inductive components from SMP for medical technology applications

SMP Sintermetalle Prometheus clean sinusoidal waveform and low- GmbH & Co KG, the German manu- loss feedback of the unused energy. facturer of soft-magnetic materials Special magnetostriction-free and inductive components based in materials, which SMP develops and Graben-Neudorf near Karlsruhe, produces according to individual has announced the development customer specifications, ensure that Components from SMP are installed of components for use in Magnetic components run very quietly. The in the gradient amplifiers which Resonance Imaging (MRI) and powder composite materials feature supply output voltages and currents Computed Tomography (CT) systems. low eddy current and magnetic Designed as filter or mains chokes, reversal losses. The components are using certain materials or appro- they claim to offer compact, low-loss noted for their low loss balances and priate, magnetically coupled designs and energy efficient components that optimal EMC properties. They are with multiple coils. are exceptionally quiet in opera- also maintenance-free. Besides medical technology, tion, essential qualities for these The three-dimensional isotropy SMP’s inductive components are demanding medical technology of the materials enables compact, used in industrial applications in applications. lightweight structures, because the power electronics, automation and In MRI scanners the components magnetic circuits are minimised. signal processing, in drive engi- are installed in the gradient ampli- This also lowers the magnetic field neering applications including railway fiers which supply output voltages strength and the quantity of winding technology, electromobility and and currents and control the gradient material used can be significantly maritime engineering, for renew- coils that encode the resonance reduced. The materials have a high able energies as well as conventional signals for subsequent image saturation induction, up to 2 Tesla, energies, and in the aerospace reconstruction. The filter and mains and the oscillation behaviour of the industry. chokes are designed to ensure a choke can be adjusted specifically by www.smp.de

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is fairly straightforward, states Finding the way forward for nuclear D’Souza-Mathew. It is defining part Powder Metallurgy applications requirements through consultation with the end users – this includes Powder Metallurgy manufacturing industry. The PowderWay project is typical dimensions of candidate methods are yet to be embraced or funded by the European Commis- reactor pressure vessel parts, as approved by the civil nuclear industry, sion through Nugenia, the European well as thermal, mechanical, fatigue, but some of Europe's major nuclear association for R&D in nuclear fission corrosion resistance and microstruc- organisations are now assessing this technologies, and is led by the UK's tural characteristics. potential, reports Mark D’Souza- Nuclear Advanced Manufacturing At the same time, the PowderWay Mathew, Metallurgist at the UK’s Research Centre. Project partners project is identifying the require- Nuclear Advanced Manufacturing include reactor developer Areva, ments and methodology for code Research Centre in Rotherham, utility group EDF, French nuclear acceptance, to determine the infor- South Yorkshire. suppliers association PNB, French mation required by the standardisa- As part of continuing efforts to energy commission CEA and Swedish tion body so it can present a robust improve the safety of future designs materials research group Swerea. code case. Before PM methods can of nuclear power plants, reactor The consortium has identified a be deployed in the European nuclear developers are exploring alterna- number of candidate components industry, they must be accepted by tive methods for fabricating reactor for PM manufacture and is now the standardisation body AFCEN. The pressure vessels. Powder Metal- consulting with end users to better consortium is exploring a route for lurgy offers several advantages over understand the benefits of PM code acceptance within the RCC-M conventional methods by removing over conventional manufacturing standards for mechanical component weak spots such as welds through methods, the acceptance criteria for fabrication. Code requirements will near-net shape manufacture. PM standardisation and the current state guide the search for available infor- parts also have reduced composi- of the art. Crucially, the research will mation in an attempt to qualify the tional segregation and a finer, more also reveal any obstacles preventing materials, manufacturing processes, consistent grain structure, which uptake of PM methods. The results benefits, limitations, testing methods is especially advantageous for bulk will be used to construct a devel- and comparative data. Gaps between non-destructive evaluation tech- opment roadmap which will guide current technology and potential niques such as ultrasonic examina- themes for future research funding. uptake will be prioritised and recom- tion. While studies have shown that This roadmap will benefit the mended in the roadmap. PM parts can meet and often exceed wider PM industry by targeting The consortium has evaluated the performance of wrought parts research funding towards improving a range of PM techniques on their under test conditions, there are resistance to harsh environmental maturity and potential for applica- areas for improvement such as high conditions, enhancing performance tion and is now focusing on three porosity, oxygen levels, inclusions and reducing ageing in PM parts. It processes: Hot Isostatic Pressing, and epitaxial effects. will also disseminate information Additive Manufacturing and Spark A consortium of reactor devel- about PM through the supply chain Plasma Sintering. Current materials opers, manufacturers and research and promote the technology to other of interest are austenitic stainless institutions are now exploring how sectors. steels, nickel-based superalloys PM can be developed for the nuclear The PowderWay project strategy and ferritic steel. The intention is to evaluate parts made from these materials in monolithic and dissim- ilar weld joint configurations. To Part requirement RCC-M code achieve this, novel and proven non- deﬁnition acceptance destructive testing techniques, which requirement are sensitive to PM-specific defects, are also under investigation. The consortium is keen to talk Determine to established members of the PM Your available industry in order to help it focus on information input required high priority areas and avoid recom- here mending R&D that is already being carried out elsewhere. Contact: Mark D’Souza-Mathew Email: [email protected] Publish Roadmap Tel: +44 (0) 7710 655002 www.namrc.co.uk

Freeman Technology to launch new POWDERMET2016 powder tester at Powtech 2016 programme now available Freeman Technology has announced which uses it will launch the Uniaxial Powder patented The Conference Programme for the Tester (UPT) at Powtech 2016, April dynamic meth- POWDERMET2016 International 19 - 21, Nüremberg, Germany. The odology, auto- Conference on Powder Metallurgy new powder tester provides an accu- mated shear and Particulate Materials is avail- rate and repeatable measure of the cells and bulk able now on the event’s website. unconfined yield strength (UYS) of a property tests The popular conference, which this powder to assess and rank flowa- to quantify the year takes place in Boston, Massa- bility. flow properties chusetts, USA, June 5 - 8, 2016, The tester is claimed to be quick, of powders. is organised by the Metal Powder reliable and easy to use, delivering Both instru- Industries Federation (MPIF) and value to scientists, process engineers ments can be will also feature a major PM trade and QC analysts working in a diverse seen on stand exhibition. range of bulk solids handling indus- #4-547, where POWDERMET2016 is being held tries. It is available in manual and representatives from Freeman Tech- in conjunction with the AMPM2016 advanced versions and is reported as nology will be on hand throughout Additive Manufacturing with Powder providing a low cost powder testing the event to discuss all aspects of Metallurgy conference. All of the solution. material characterisation. There will technical sessions, special events Alongside the UPT, the company also be an opportunity to hear about and exhibition will be shared and continues to provide a comprehensive the company’s latest research during open to delegates of both events. powder characterisation solution Partec, the conference running www.powdermet2016.org in the FT4 Powder Rheometer®, alongside Powtech. www.ampm2016.org a unique universal powder tester, www.freemantech.co.uk

Metal powders may offer alternative to Wolfson Centre fossil fuels announces short

The use of metal powders to power courses aimed at external combustion engines powder handling could offer a viable alternative to the use of fossil fuels, according industries to researchers at Canada’s McGill University in Montréal, Québec. In The Wolfson Centre for Bulk Solids a study published in the journal Handling Technology, part of the Applied Energy, the energy and power School of Engineering at the Univer- densities of the proposed metal sity of Greenwich, UK, is running Mechanical Engineering Professor fuelled zero carbon heat engines are a programme of short courses Jeff Bergthorson predicted to be close to current fossil throughout 2016 designed to attract engineers from industry working in fuelled internal combustion engines, “Biofuels can be part of the solu- the area of bulk solids handling or making them an attractive technology tion, but won’t be able to satisfy all the flow of powders. for a future low carbon society. the demand; hydrogen requires big, Courses are aimed at engineers, “Technologies to generate clean heavy fuel tanks and is explosive managers, skilled operatives, main- electricity – primarily solar and wind and batteries are too bulky and don’t tenance crew or anyone involved in power – are being developed rapidly; store enough energy for many appli- using powders or particulates and but we can’t use that electricity for cations,” stated Bergthorson. “Using include: many of the things that oil and gas metal powders as recyclable fuels are used for today, such as trans- that store clean primary energy for • Electrostatics in Powder portation and global energy trade,” later use is a very promising alterna- Handling states the lead author of the study, tive solution.” • Powder and Dust Containment Professor Jeffrey Bergthorson, a Unlike the internal-combustion in the Process Industry mechanical engineering professor engines used in gasoline-powered • Network Security of Industrial and Associate Director of the Trot- cars, external-combustion engines Control Systems in the Process tier Institute for Sustainability in use heat from an outside source to Industry Engineering and Design at McGill drive an engine. External-combustion University. engines, modern versions of coal • Dust Explosions – How to When burned, metal powders fired steam locomotives, are widely Demonstrate DSEAR/ATEX react with air to form stable, used to generate power from nuclear, Compliance nontoxic solid-oxide products that coal or biomass fuels in power • Caking and Lump Formation in can be collected relatively easily stations. Powders and Bulk Solids for recycling, unlike the CO2 emis- While laboratory work at McGill • Undesired De-blending and sions from burning fossil fuels that and elsewhere has shown that the Separation in Processes and escape into the atmosphere, state use of metal fuels with heat engines Equipment the researchers. Iron powder could is technically feasible, no one has yet • Introduction to Processing of be the primary candidate for this demonstrated the idea in practice. Dry Solid Materials; An overview purpose, according to the study, as it The next step toward turning the of core processing methods for is readily recyclable with well-estab- laboratory findings into usable tech- powders and granules lished technologies and some novel nology, therefore, will be “to build a • Measurement of the Properties techniques can avoid the carbon prototype burner and couple it to a and Bulk Behaviour of Powders dioxide emissions associated with heat engine,” added Bergthorson. and Particulate Materials traditional iron production using coal. www.mcgill.ca www.bulksolids.com

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To submit news to PM Review please contact Paul Whittaker: When burned, metal powders react with air to form stable, nontoxic solid-oxide [email protected] products that can be collected relatively easily for recycling

Exhibition Area Extended New Stands Available Hamburg, Germany 9 - 13 October 2016

Organised and Sponsored by

INDIA FOCUS The challenges and outlook for India’s Powder Exhibition Area Extended Metallurgy industry New Stands Available During a visit to India on behalf of Powder Metallurgy Review, Dr Georg Schlieper took the opportunity to meet with Narasimhan Gopinath, President of Powder Metallurgy Association of India (PMAI). During Hamburg, Germany the meeting, Gopinath answered questions regarding the current state of India’s PM industry and provided his unique perspective on the 9 - 13 October 2016 opportunities for growth in the country

India is a significant producer and wheelers from April 2014 to March In the following interview, the consumer of Powder Metallurgy 2015 as against 21,500,165 from President of PMAI and owner of components, as well as being an April 2013 to March 2014, registering India’s largest manufacturer of PM important member of the interna- a growth of 8.68% over the same furnaces, Narasimhan Gopinath tional PM community. The country period. The country exported some (Fig. 1), shares his knowledge of has numerous PM parts makers as 3,573,806 vehicles from April 2014 to India’s PM industry and provides his well as a full supply chain including March 2015 and recorded domestic views on the future growth potential equipment manufacturers and sales of 19,752,580 for passenger for the region. powder suppliers. There is much vehicles, commercial vehicles, three research and development under- and two wheelers in the period [2]. taken at India’s academic institutions The Powder Metallurgy Asso- and research laboratories, evident by ciation of India (PMAI) was founded the high number of technical pres- in 1973 and members included entations made both nationally and scientists employed in government internationally by representatives of owned defence research laborato- these organisations. ries, factories and the department of It is estimated that total produc- atomic energy, as well as academics Organised and Sponsored by tion of iron-base PM components in and representatives from India’s India reached 30,500 tons in 2015, fledgling Powder Metallurgy industry. with copper base parts reaching Today, members are predominantly 9,800 tons. Around 76% of the PM from the PM industry and the PMAI components produced in the region serves as an effective trade associa- are destined for the automotive tion in terms of government liaison sector [1]. and trade promotion. It organises The automotive industry in India workshops and a popular annual produced a total of 23,366,246 vehi- conference as well as publishing peer Fig. 1 Narasimhan Gopinath, cles including passenger vehicles, reviewed articles in the bi-annual President of the PMAI, presents his www.worldpm2016.com commercial vehicles, three and two PMAI Transactions. view of India’s PM industry

Indian manufacturer of aluminium PM parts for the automobile industry.

Is there an opportunity to introduce innovative technologies in India? Gopinath: In the past it was not easy for Indian PM manufacturers to implement innovative technologies. If, for example, an Indian company wanted to convert a shock absorber piston to sintered aluminium, they need a buyer who was invariably located outside India, who would probably prefer a part maker and Fig. 2 GKN Sinter Metals, formerly known as Mahindra Sintered Products near R&D institution who are located Pune, is India’s largest PM component manufacturer (Courtesy GKN) more conveniently to them. This situation is now changing India’s Powder Metallurgy Porite who recently broke ground in with the rise of Indian automobile manufacturers, especially Tata parts industry Pune. It is also likely that PMG will set up shop soon. Motors and Mahnidra, as well as the large R&D centres set up by What are the major structural There is a relatively strong overseas auto makers in India. PM parts companies in India and industry in India producing house- where are they located? hold appliances. These have a high Are there any companies applying Gopinath: The development of the demand for sintered bearings which Hot or Cold Isostatic Pressing in Powder Metallurgy industry in India is supplied by around 24 smaller India? is, as elsewhere, strongly linked PM companies producing mainly Gopinath: Hot Isostatic Presses are to the growth of the automotive bushes and a few structural parts. currently only installed in research sector. The major automobile Of course, there is a wide variety laboratories. They are mainly used centres in the country are located of other applications outside the for technological development and in the regions of Chennai, Pune, automobile sector such as machine only occasionally for industrial jobs. Delhi and more recently the region building, machine tools, conveyors, There are several Cold Isostatic of Gujarat, therefore the majority of agricultural appliances and now, in Pressing facilities producing filter PM companies can also be found an increasing quantity, power tools. candles from bronze. in these regions in order to supply this sector. Are there manufacturers of porous The largest PM company in sintered products in India? Magnetic components the country is without question Gopinath: Among several manu- GKN Sinter Metals (Fig. 2), which facturers of bronze filters in India What about the ferrite industry in was formerly Mahindra Sintered are Vora, Kulkarni, Star Sintered India? Products and is located in Pune. Products and six others. The main Gopinath: Low cost imports from Following GKN in this list is application is for silencers on pneu- China almost wiped out the Indian Sundram Fasteners, located in matic cylinders, flame arrestors and ferrite industry. Today however, Hosur, near Bangalore. Between pressure regulator parts. Stainless perhaps due in part to increasingly them they supply over half the steel filters are not produced in stringent quality requirements and market share of automotive PM. India. the increased prices of Chinese About 10% of India’s automobile imports, there is a resurgence in PM parts consumption is imported Is there an industry for PM light India’s ferrite industry. Cosmo is the from Japan, Europe and the metals such as aluminium and largest manufacturer, with about United States, with the remainder titanium? 500 tons per year, followed by Mahi- manufactured in India by other Gopinath: Lightweight components ndra CIE with 300 tons per year, PM companies such as Speciality made by aluminium PM, especially then Delta and SSP each with some Sintered Products, Federal-Mogul, composites and titanium are being 200 tons per year. There are also Hitachi, Sintercom, Tenneco, Moth- manufactured by a variety of routes about six other smaller manufac- erson, Star Sintered Products, NPR for defence and aerospace applica- turers totalling a further 100 tons and a few others. A new entrant is tions. However, there is presently no per year.

Metal Injection Moulding Diamond tools, hard And how are the hardmetals and and Additive Manufacturing materials and heavy heavy metal industries fairing? metals Gopinath: The tungsten carbide How do you assess the situation of industry is also doing well. Indian and the Indian Metal Injection Moulding What is the situation of the Indian international companies servicing industry? diamond tool industry ? India’s industry included Sandvik Gopinath: The Metal Injection Gopinath: The Indian diamond tool (Fig. 4), Electronica, Rapicut, Seco, Moulding industry in India is domi- industry (beads and segments) Kennametal, TaeguTec, Sumitomo nated by a single company, Indo-US mainly focused on cutting granite and Seco Tools. There are also at MIM (Fig. 3), who supplies MIM stones, is thriving. The traditional least half a dozen smaller companies parts worldwide. Four other MIM manufacturing method of hot supplying specialised or niche prod- manufacturers in India, with less pressing is being replaced gradually ucts, where they can compete against installed capacity, have recently been with ‘free sintering’ which becomes the larger players by offering smaller established, with the largest of these mandatory for small beads used batches for example. being MIM Components (Bangalore) in multi strand cutting machines. The fact that tungsten and cobalt Ltd. The major suppliers are StaySharp, are not mined in India is not an The reason why MIM has not yet Optima, SD Tools and Diabu who impediment given the capacity of developed on a wider scale is that supply over half the market. The local recycling plants and imports by most products where MIM parts remainder is supplied by over Indian owned overseas mines. Heavy are used, for example computers, fifty other small manufacturers, metal, mainly tungsten, parts are mobile phones, firearms, medical some of whom such as Sanwa and made in bulk by the Indian Ordnance devices and consumer products, Korgavkar make high quality and Factory as well as to a smaller extent are not produced in India in large exotic beads. The concrete cutting by Innomet, who is also a manufac- quantities. If there existed a larger sector is served by Hilti, Wendt as turer of nickel, stainless and HSS domestic market for MIM parts, the well as several others. powder. country would clearly have more MIM companies. This situation is, however, likely to change following a tentative foray into MIM by the Pune based Indian multinational Bharat Forge, the world’s largest forging company and the country’s largest manufacturer and exporter of automotive components. There are also a number of MIM incubation centres being set up to help promote the technology.

Are there activities in metal Additive Manufacturing? Fig. 3 MIM components made by Indo-US MIM Tec Pvt. Ltd, have earned Gopinath: At present there are a international awards. These parts received the 2014 MPIF Grand Prize in the relatively small number of Additive Automotive - Engine Category (Courtesy MPIF, USA) Manufacturing machines installed in India. However, I expect that progress in AM will not be as slow as it was for MIM in India. Additive Manufacturing machines, mainly from EOS, are being imported in increasing numbers and there are already three manufacturers of 3D printers (for ABS) in Mumbai and Bangalore. I think a major impetus for AM will come from the jewellery sector as gold is extremely popular in India. A number of designs for AM rings and bracelets were displayed at the PMAI’s recent PM16 confer- Fig. 4 In 1956 the Government of India invited Sandvik in Sweden to set up a ence held in Pune. cemented-carbide manufacturing factory in India (Courtesy Sandvik)

produced mainly by Kandoi, PP Patel and Star Sintered. Of course, bronze bearings are a big market for copper powder, but there are other consumers of copper powder outside of PM. Several producers of bimetal bearings have their own in-house production of copper powder. Copper powder is used extensively by manufacturers of diamond tools, catalysts and electrical contacts. MEPCO in the temple city of Madurai is one of Asia’s largest manufacturers of aluminium powder with a capacity of 30,000 tons per year, however the main use for this powder is in India’s large fireworks and paint industries. They have about half of the Indian market with Arasan, Sun Ark and two others sharing the remaining.

Let us talk about equipment suppliers. Are powder presses built in India? Gopinath: There are a number of manufacturers of mechanical compacting and sizing presses suited to Powder Metallurgy. The leading supplier is Newmet who has an installed base of over 500 presses, mainly for the manufacture of Fig. 5 Electropneumatics & Hydraulics (I) Pvt Ltd, Pune, designs and manufac- bearing bushes and diamond tools. tures standard and customised metal forming equipment. The pictured press is Hydraulic presses are available from the company’s 500T CNC Hydraulic Powder Compacting Press Electropneumatic (Fig. 5) as well as Yugantak and Glassnost. However Powder and equipment Rio Tinto has announced plans to most of these presses are imported suppliers invest in an iron powder annealing from Europe (200 from Dorst alone) and blending plant in Gujarat with an and of late from China. The Chinese What metal powder production is annual output of 60,000 tons. presses are said to be reasonably there in India? Many Indian powder manufac- good and of course much cheaper Gopinath: There are several produc- turers have been concerned about than similar European presses. tion plants for iron powder. Höganäs imports from China following the Therefore a large number have been has a factory atomising approxi- removal of export duty on iron powder installed in Indian PM companies. mately 20,000 tons per year. Sundram exports from the country. However, Fasteners has its own iron powder these fears have not yet been realised As the owner and Managing Director atomising facility with a capacity of on account of concurrent removal of Fluidtherm you have an intimate approximately 9,000 tons. Smaller of export benefits and due to the insight into the Indian manufac- manufacturers sell around 6000 fact that Indian iron powder is now turers of sintering furnaces tons per year of atomised and mill competitively priced. Moreover, it is Gopinath: It seems almost all estab- scale sponge iron powder. Most of not easy to change the iron powder lished Indian furnace manufacturers their powder goes to smaller PM supplier for existing products as have supplied at least one sintering part makers as well as for welding the dimensional changes are often furnace to one or other segment of electrodes. different and a change of the iron the Indian PM industry. Fluidtherm Industrial Metal Powders Ltd., powder may require new tooling. however is a specialised manufac- located in Pune, is one of the world’s Copper powder production is turer of furnaces for Powder Metal- largest manufacturers of high quality remarkably strong in India with lurgy with several furnaces shipped electrolytic iron powder. about 13,800 tons per year being to OEM furnace makers in Germany.

Apart from installing furnaces Challenges to the growth of What are your expectations for the at most major Indian PM part India’s PM sector future of PM in India? makers we also sell directly to part Gopinath: With the increasing makers in South Korea and China. What challenges does India face to number of research organisations in In addition to Fluidtherm there are the growth of its PM industry? the country there is a possibility that four other PM furnace manufac- Gopinath: Improvements to the the Indian PM industry can become turers who serve the Indian market, country’s infrastructure are a prime more innovative and gradually close the largest among them being requirement for industrial growth, a the technological gap between India Malhotra Engineers. job that is perhaps easier to achieve and the Western industries. Cremer, Sinterite and CM in a country which is not a multi- We have a middle class in society Furnaces have all supplied contin- cultural, multi- religious, vibrant that is expected to grow to several uous furnaces to India PM compa- democracy such as India. In many times the size it is now. This will help nies. Ipsen, GM Furnaces and Elnik regions there is a shortage of good create an increasing demand for have supplied MIM furnaces. roads and the cities are already vehicles and luxury goods. crowded, meaning that it might be One major resource is that we difficult to build more roads or facto- have millions of children and young Research and academic ries. It is not possible to tear down people today who will soon grow to institutions “In my opinion the Indian economy is How many academic institutions or research organisations are very strong because of the nature of concerned with Powder Metal- its people” lurgy? Gopinath: At our annual PMAI conferences approximately 200 historic structures to build roads. make up a massive workforce. papers are submitted every year by Furthermore, regional bureaucracy Over the next five years we expect more than 25 academic institutions can also slow down the process. a growth in car sales of around 5% and research laboratories, of which The region of Gujarat, however, is annually. The growth of automobile we select about 75 for presenta- a good example of how improvements parts manufacturers will be higher, tion. Main contributors are from to infrastructure can lead to growth. probably between 15 and 20% annu- research laboratories from the During his time as Chief Minister of ally due to increasing export oppor- nuclear and defence establishment, Gujarat, Narendra Modi, now India’s tunities. By 2050 we expect to be seven of the eleven Indian Institutes Prime Minister, worked hard to attract the second or third largest vehicle of Technology and several other the automobile industry to the region. manufacturer in the world. institutions. Gujarat’s infrastructure was improved Even with the challenges of Governmental research institutions with new transport links, along with improving India’s infrastructure I am are often defence oriented and offering tax breaks to encourage auto confident that the Indian PM industry work at the front fields of science, makers to establish factories in the will remain in a good position. but they also sell their technolo- area. The policy proved successful, gies as a spin-off to the private with Tata Motors, the largest Indian sector. There is also a non-military owned automobile company, setting Author research organisation with many up a plant there to build the world’s Dr Georg Schlieper laboratories located all over India. cheapest car, the Nano. They are not Gammatec Engineering GmbH Last year the PMAI began alone, other auto makers such as Mermbacher Strasse 28 presenting an award for the best Suzuki, Ford, Mahindra’s, Fiat and the D-42477 Radevormwald, Germany paper at its annual PM confer- light commercial vehicles specialist, E-mail: [email protected] ence. Entry is open to students and Force Motors have followed suit. young professionals who are not Today other states compete supported by a company. The award against each other and try to attract References winner receives a fully paid trip to as much investment as possible, often an international PM conference at the cost of other regions. [1] Status of PM in India, N. Gopinath and the winner last year (Fig. 5) In my opinion the Indian economy President, PMAI (Fluidtherm) as was sent to POWDERMET2015 in is very strong because of the nature of presented at PM16, Pune, India. San Diego, USA. The winner of the its people. However, with a population [2] Society of Indian Automobile recent PM16 conference, a student of over one billion, there are chal- Manufacturers (SIAM) http://www. from a Spanish University will lenges in getting the economic gains siamindia.com attend the PM World Congress in of industrialisation to the disadvan- Hamburg, Germany. taged section of the population.

INDIA FOCUS Fluidtherm Technology: India’s innovative furnace manufacturer looks forward to continued growth

Fluidtherm Technology Pvt Ltd is India’s largest manufacturer of furnaces for the Powder Metallurgy industry. The company is one of the industry’s leading innovators, regularly presenting its technological developments at international conferences and exhibitions. Dr Georg Schlieper recently visited Fluidtherm and met with the company’s founder and CEO, Narasimhan Gopinath. In this exclusive report for Powder Metallurgy Review, we review the growth of Fluidtherm and reasons for its continued success

Fluidtherm manufactures a wide date well, when I gave notice to all my resources, enough to buy a couple range of furnaces for heat treatment, principals and we got into manufac- of welding machines and tools, and chemical processing and Powder turing. Had I an inkling of what this together with his committed team, he Metallurgy (PM) at its site in Chennai, would entail I would have opened a began to produce spare parts for heat India, where the company also oper- laundry instead!” However ignorance treatment furnaces such as mesh ates an in-house R&D and thermal is bliss and so with modest financial baskets, muffles, fans, etc. “After process prototyping and optimisation facility. The history of Fluidtherm is closely linked to the biography of its founder and CEO, Narasimhan Gopi- nath. Soon after his graduation from Delhi University, Gopinath established a sales agency selling capital goods such as cranes, conveyors, presses and heat treatment furnaces in his hometown, Chennai. He also employed a small team of engineers to provide installation and after-sales services. “This business, which lasted from 1975 to 1982, was enjoyable and stress free but I felt we were not real- ising our full potential” commented Gopinath. “It was the 7th of Fig. 1 One of two sinter hardening mesh belt furnace installed at one of September 1982, I still remember the Fluidtherm’s customers, Daekwang Sintermetal, in South Korea

seven years as a salesman, getting to meet the then leading manu- supplier of high quality heat treat- orders was not a problem although facturer for technology licensing. ment furnaces. the market was very weak at that However, their installed base was As time passed Fluidtherm time with just two car makers, two modest but their licence fee was started manufacturing continuous truck makers and five two wheeler not.” Gopinath therefore decided to hardening and tempering furnaces manufacturers, all of whose capacity develop this on his own. “Lessons as well as annealing, brazing and was limited by licences issued by the were learnt from early failures sintering furnaces for Indian auto then socialist government,” stated and in a short time we set up a part makers. In the late 1990s a Gopinath. successful demonstration plant.” close cooperation developed with a German annealing furnace maker and for many years Fluidtherm “We got into PM seriously when we supplied parts of, and whole furnaces installed sintering furnaces at the Federal to, them and to two other German furnace makers. Mogul (then Brico) valve seat and valve “We got into PM seriously when guide plant in India” we installed sintering furnaces at the Federal Mogul (then Brico) valve seat and valve guide plant in India. After a few years the Indian Fluidtherm Technology Pvt. Ltd. In the early 2000s we were invited to economy began to grow and the was incorporated in 1985 and moved visit a prominent German firm, with company began to prosper. With into its present location in 1989 for strong PM credentials, for discus- a bank loan in 1984, Gopinath the manufacture of fluidised bed sions and finalisation of a strategic established Magnatherm Alloys, a furnaces and operation of a process partnership,” says Gopinath. The foundry for in-house manufacture of prototyping facility and laboratory. agreement, which kept Fluidtherm previously out sourced heat resisting The company received many orders out of Europe and USA, lasted for steel castings such as furnace thanks to increased environmental about ten years until the ownership jigs, pusher trays, etc, used in heat awareness and a total of around of this firm changed hands. “While treatment furnaces. In due course 400 fluidised bed furnaces were we already had creativity, a scientific there came a desire to upgrade from built and delivered in the first ten temper and a fundamental knowl- making parts of furnaces to whole years, and some 534 to date. “This edge of metallurgy and engineering, furnaces. At that time environmental achievement got us the prestigious we remain grateful to all our German authorities were legislating against ‘National Award for Technology OEM customers for introducing us the large number of cyanide salt Development’ from the Govern- to European standards, their best bath heat treatment furnaces across ment of India, the closest thing to a practices and their manufacturing India, so an environmentally friend- Nobel prize that Indian industry can systems,” stated Gopinath. lier alternative was required. expect for technological achieve- During this period there was a “I had heard of the concept of ment,” added Gopinath. Fluidtherm steady increase in the number of fluidised bed heat treatment, an became well-known and highly Fluidtherm installations in India. environmental friendly alternative to regarded among engineers in the OEMs and PM part makers from salt baths so I travelled to the USA Indian metalworking industry as a Europe and North America, who had

Fig. 2 Today Fluidtherm manufactures furnaces suited to a wide range of applications. Shown here is a continuous nitrocarburising (heat treatment) furnace

established joint ventures in India where Fluidtherm furnaces were used, found that the parts sintered or heat treated in these furnaces were of high quality. This led to exports to their manufacturing facilities in South-East Asia, specifi - cally in South Korea and China. Fig.5 The surface structure of an N9 Pownited sample shows a shallow layer of iron nitride Later furnaces were supplied to with a substrate of bainite. non-affiliated locally owned PM part makers in these regions. Hardness was measured across the cross section of Pownited bushes to check the Fig. 3 Microstructure of Pownite® heat treatment, surface (left) and core Fluidtherm has an annual surface to core variation and this was compared with ‘as sintered’ and quench & tempered production rate of around 25 bushes. (Figs. 6 and 7) furnaces which are manufactured by a permanent workforce of 42 at its 700 Note: AS - As sintered, HT - Hardened & Tempered 4050 m² site. At least two appren- ticeship positions are offered each 600 year. 500

In-house R&D that is 400 unique in this sectorHardness Vickers 300

Research at Fluidtherm began in the Vickers Hardness 200 late 1980s with the establishment 100 A 0.5%C, 6.8 g/cc B 0.5%C, 7.2 g/cc C 0.8%C, 6.8 g/cc of an in-house R&D laboratory and D 0.9%C, 7.2 g/cc AS 0.5%C, 6.8 g/cc AS 0.9%C, 7.2 g/cc thermal process prototyping facility. HT0.5%C, 6.8 g/cc HT 0.9%C, 7.2 g/cc 0 This was one of the first investments 0 0.3 0.6 0.9 1.2 1.5 by the company as the design of Depth in mm their furnaces, made without help from any licensor, required much Fig. 6 – Hardness profile of "Through Pownited" bushes (experiment N5) Fig. 4 Hardness profile of Pownite® processed 2%Cu + 0.5% C sintered bushes fundamental development work. “The difference between a licensor and a licensee is not intellectual atmosphere containing precisely Fe-Cu-C steels containing 0.5 - capability, it is the mistakes made controlled amounts of ammonia. 0.8% C as well as low alloy steels previously from which the licensor Nascent nitrogen (from the with resulting improvement in hard- has learnt before the licensee came breakdown of ammonia) diffuses ness and mechanical properties. along. We needed this facility in into the surface of the parts, but As the process does not require oil which to make our mistakes, so the purpose is not to form a surface quenching, the parts are free from that our customers got equipment layer of iron nitride as is the case impregnated oil after hardening and processes that worked without of the nitriding processes. Instead, and exhibit less distortion than oil trouble,” commented Gopinath. nitrogen is diffused through the quenched parts. The research carried out at section thickness of the part due Fig. 3 shows the microstruc- the Fluidtherm facility is not only to interconnected porosity and ture of a Fe-2%Cu-0.5%C sintered related to furnace design, but also austenite is formed by this nitrogen steel after Pownite® processing. to the development of innovative diffusion at a temperature above At the surface there is hard bainite heat treatment processes. The the eutectoid point in Fe-N-C (dark) and some ferrite (white) but most recent of over 40 development ternary system. This austenite can no nitrides are visible. The micro- projects are the novel Pownite® and optionally be converted to bainite structure in the core contains more CCGQ (continuous carburising gas and hard transformation product ferrite (white) and also some bainite quenching) processes. by ageing the parts between 250°C (dark). and 550°C. Hardness profiles of Fe-2%Cu Pownite® gas alloying process Variations of the process allow PM steels with varying density and The Pownite® process, for which diffusion of a fairly uniform extent carbon content after Pownite® Fluidtherm has applied for patents, of nitrogen throughout the part or, processing are shown in Fig. 4. All is a process for strengthening the if desired for wear applications, in a samples exhibited microhardness matrix of a sintered part by gas concentration near the surface akin at the surface of roughly 500 HV and alloying. The process is carried out to case hardening. the core hardness was between 300 between 590°C and 700°C in an Pownite® is applied to plain and 400 HV.

Fig. 5 Gear tooth test fixture (left) and clean break shown after testing (right) Fig. 6 Macrostructure of the gear tooth The CCGQ process becoming brittle. The defined case bright parts would be a bonus. The The CCGQ process (also patent with a sharp drop in hardness after similarity with a mesh belt sintering applied) is under production scale a given depth, is made possible by furnace should make it user friendly development to provide a defined reducing the quenching intensity to the PM industry. carburised case in Powder Metal- by the use of atmospheric pressure Fig. 5 shows the clean break of lurgy parts typically made in powder gas quenching. a gear tooth after testing. Fig. 6 grades similar to Astaloy 85Mo. Parts will typically be carbur- shows the macrostructure of a This process is an alternative ised in a continuous mesh belt martensitic case of a gear tooth in to traditional atmosphere case furnace very much like a sintering Astaloy 85Mo which was carburised hardening and oil quenching which furnace and then quenched in what and gas quenched as described usually results in the entire section is essentially a sinter hardening above. of the part being hardened and thus module. Reduction in distortion and

Steel Continuous Mesh Walking Bell / strip Graphite Fluidised Furnace type Pusher hardening Retort Laboratory belt beam elevator conv- tube bed tray mesh belt eyor Sintering • • • • • • High Temperature Sintering • • • • Sinter Hardening • • • • Steam Treatment • • • • Aluminium Sintering • • • Heat Treatment • • • • Powder Annealing, Reduction, Carbur- • • • • • • ising Hardmetals • • • • MIM • • • Ceramics • • • • • Diamond Tools • • • Friction Materials • • • •

Table 1 Furnaces for Powder Metallurgy available from Fluidtherm

Fig. 7 Mesh belt sintering furnace

Full range of furnaces for Powder Metallurgy and heat treatment applications

Fluidtherm offers a full range of furnaces for the PM industry, including powder annealing furnaces as well as mesh belt, walking beam and pusher furnaces for the sintering, steam treatment and heat treatment of PM parts (Table 1). Apart from general engineering software, Fluidtherm makes extensive use of CFD packages such as ANSYS and FLUENT for structural stress analyses of furnace components, modelling convection ducts and transient thermal analyses. Below are a number of highlights and Fig. 8 Sinter hardening furnace special features that demonstrate the high technical competence of under a N2 + H2 sintering atmos- compared to the traditional prac- Fluidtherm’s engineering. phere, are offered in addition to tice of reheating and oil quenching. furnaces with rapid debinding in a Additional advantages include Mesh belt furnaces well proven direct gas fired chamber lower distortion due to the absence The industry standard mesh belt (RBO). When used along with an of a vapour blanket, bright parts, furnace (Fig. 7) has today reached endogas atmosphere from either an elimination of oil contamination of a high level of sophistication, with internal or external gas generator, the parts and washing (thus less near zero downtime other than for this allows significant cost savings pollution). The cooling rate can be belt changing. Total automation is especially in locations where gas is adjusted within limits and quench achieved that includes supervised cheap. cracks are eliminated. loading, discharging and entering The Fluidtherm sinter hardening an idling mode without operator Sinter hardening furnace (Fig. 8) was developed with intervention when production is inter- The main advantages of sinter the help of modelling from the rupted. State-of-the-art software for hardening, done by gas quenching FLUENT software and the help of safe and efficient furnace operation sintered parts as they emerge the nearby Indian Institute of Tech- is completely developed in-house. from the sintering section of the nology. It applies convection cooling Mesh belt furnaces, where gradual furnace (in an integrated module), by turbulent flow caused by a nozzle debinding is performed in a muffle is a reduction in manufacturing cost field through which the same

furnace atmosphere gas, nothing extra needed, is re-circulated by a Initial Stage Orientation Grain boundary development blower across a heat exchanger. The cooling rate depends on component geometry, belt loading, blower speed and belt speed. The maximum cooling rate recorded in production conditions is 8.6°C/second. Al + Sn + Mg Transient liquid phase Al O skins cracked 2 3 In an effort to make sinter hardening applicable to low alloy Growth of contacts Pore closure & PM parts, Fluidtherm is working on densification a continuous sintering plant with pressure gas quenching.

Continuous aluminium sintering furnace Diffusion of Al Sintering of aluminium powder compacts poses special challenges Fig. 9 The five stages ofaluminium sintering: powder compaction, particle to the furnace design due to the orientation, grain boundary development, contact growth and densification adherent skin of alumina on the powder. Critical conditions for high quality sintering are a very high Pusher tray, Sintering section degree of temperature uniformity 600 mm Sq. x • Hot gas recirculation (±3°C), 100% nitrogen atmosphere 100 mm deep • Gas impingement for with very low contamination (max Dewax section rapid heat transfer 3 ppm oxygen and - 70°C dew point) and the elimination of debinding atmosphere ingress into the sintering section. The five sintering stages are shown schematically in Fig. 9. After delubrication, and shortly before the sintering temperature is reached, 24112 a liquid phase forms and allows Entry lock chamber Intermediate lock Water jacketed the aluminium powder particles to to prevent air ingress chambers to prevent cooling change their orientation. The forma- binder fume ingress to Exit lock chamber to tion of spinel (MgAl O ) absorbs the sintering section prevent air ingress 2 4 most of the oxygen contained on the particle surfaces so that the Fig. 10 Schematic layout of an aluminium sintering furnace diffusion barriers are removed. Neck

Fig. 11 Aluminium sintering furnace

formation occurs followed by pore closure and densification. The aluminium sintering furnaces designed by Fluidtherm are characterised by an all metal hot zone that allows maintenance of atmosphere integrity lower than 2 ppm oxygen and -70°C dew point throughout the sintering section. A special baffle system is employed to insulate the heater radiation from the workload. Uniform heat transfer is effected by jet impingement so ±2°C is maintained in the sintering and delubrication sections. Atmos- phere lock chambers are placed at the entry, exit and between the delubrication and the sintering sections in order to prevent the exchange of gas, see Fig. 10 and Fig. 11. Fig. 12 Continuous pusher steam treatment furnace Continuous steam treatment furnaces Steam treatment is an exposure of PM parts to steam at approximately 540°C, so a firmly adherent surface layer of iron oxide Fe3O4 is formed not only on the outer surface, but also inside the pores. The process is generally applied to PM parts used in automotive brakes and compres- sors to improve the hardness, wear resistance and corrosion resistance. The continuous steam treatment furnace developed by Fluidtherm has a pusher type transport mechanism instead of the otherwise common mesh belt mechanism (Fig. 12). This furnace utilises humidified nitrogen in place of steam. Conventional mesh belt steam treatment furnaces are necessarily Fig. 13 High temperature sintering furnace open at both ends. Over 90% of the steam consumed is needed to High temperature sintering furnace design where binder removal keep air out of the furnace and the furnaces is done in a parallel track. Encapsu- remainder meets the thermody- Fluidtherm has installed several lated fans for enhancing the cooling namic requirement of the process. high temperature pusher furnaces rate reduce the overall size of the The Fluidtherm furnace keeps air designed for operation at 1350°C equipment. out of the furnace with the use of to 1450°C for sintering iron and Internal muffles eliminate hot atmosphere lock doors at both ends. stainless steel parts and 1700°C for spots and this not only improves This reduces the gas consump- hardmetal, tungsten and uranium the temperature uniformity, it also tion dramatically and, in addition, oxide sintering (Fig. 13). A sophis- improves the purity of atmosphere enables processing under pressure. ticated programmable pusher the parts are exposed to. The This makes the use of humidified system ensures negligible vibration increasing use of high sintering nitrogen, the generation of which during transport and a consequent temperatures for automobile struc- needs much less energy than steam, increase in the length and produc- tural parts requires the use of large possible. tion capacity of the furnaces. This is capacity furnaces, typically with a further increased by the use of a split tray size of 500 mm x 460 mm, twenty

mind-set and the vast technological infrastructure here. India has a large, educated and English speaking workforce, with a customer first attitude,” added Gopinath. A new building at Fluidtherm’s facility in Chennai is currently under construction to increase production capacity. The company is also actively seeking to expand its network of international agents and partners. “We have an attractive deal for entrepreneurs in ‘open’ regions and are looking for takers,” concluded Gopinath.

Contact N. Gopinath Fig. 14 Gears in stacked trays emerging from a high temperature sintering Fluidtherm Technology Pvt. Ltd. furnace with a capacity of 420 Kg/hr SP132, III Main Road Ambattur Industrial Estate trays per hour and a net production cations including heat treatment, Chennai 600 058, India capacity of over 500 kg/hr (Fig. 14). chemical processing and Powder Phone: +91 44 26357390 Large furnaces that use 100% Metallurgy. Although the company Email: [email protected] hydrogen atmosphere utilise is now the largest manufacturer of www.fluidtherm.com specially engineered vacuum locks PM furnaces in India, it is not just the which keep the furnace atmosphere Indian PM industry that is responsible Author pure and at the same time reduce the for its continued growth. Fluidtherm gas consumption. Gas tight internal relies strongly on the international Dr. Georg Schlieper doors allow the use of different sales of its furnaces and sees many Alleestr. 101 atmospheres in different sections of opportunities for further increasing 42853 Remscheid, Germany the furnace and isolate one section these exports. Phone: +49 2195 6889274 from the gases of others. “The current low demand for www.gammatec.com Powder Metallurgy furnaces in India Email: [email protected] Strong exports and further cannot sustain Fluidtherm,” stated growth Gopinath. “In 2015, 83% of our turnover came from exports, mostly Fluidtherm is a specialist enterprise to South Korea and China, thanks to with all the necessary in-house our local partners.” resources for the development, “I think we have several good manufacture and installation of things going for us, not just our furnaces for a wide range of appli- technology, but our developmental

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China’s cemented carbide industry: Growth prospects for the world’s leading producer

Cemented carbide production has been one of the fastest growing segments of Powder Metallurgy with tonnage estimated at around 65,000 mt globally in 2014. China is the leading global manufacturer of cemented carbides with over 40% market share. In the following report Zhongjian Zhang, President of the Cemented Carbide Branch of the China Tungsten Industry Association, identifies the key players and reports on the current state and outlook for the cemented carbide industry in China.

Cemented carbides, or hardmetals as Cemented carbide production 65,000 mt globally in 2014. Of this they are commonly known in Europe, Cemented carbide production has total, China accounted for 27,000 mt are Powder Metallurgy products been one of the fastest growing in 2014 which makes the country based primarily on tungsten carbide segments of Powder Metallurgy the leading global manufacturer bonded with cobalt. Invented in with tonnage estimated at around of cemented carbides, with over Germany in 1923, the first commercial application was for drawing dies to produce tungsten wire and these were soon followed by cutting tools for the machining of metals. Cemented carbide cutting tools are today among the most widely used products for turning, milling, cutting, grooving, thread cutting, drilling and boring of metals and other materials in sectors such as automotive production, aerospace, railways, energy generation, etc. However, the applications for cemented carbides have also expanded into other areas such as mining tools, construction and civil engineering, oil and gas drilling tools and wear resistant parts Fig. 1 Cemented carbide tools are used in many applications including mining, for chipless forming (Fig. 1). oil exploration and rock drilling (Courtesy Zhuzhou Cemented Carbide Corp)

40% market share (Fig. 2). Sales Output of cemented carbide products in China revenue for cemented carbides

30000 produced in China in 2014 stood 27000 at RMB 22 billion (Fig. 3). It is, however, no coincidence that 25000 22000 China’s dominant position in this market is due to the fact that the 20000 country holds almost 30% of the world’s tungsten ore reserves and 15000 14000 that China accounts for around 87%

Output /Ton of the world’s tungsten output. The 10000 8189 country also accounts for 50% of 7100 the world’s tungsten consumption 5000 and 80% of the volume of tungsten traded globally. Exports reached 0 1995 2000 2005 2010 2014 6,780 mt in 2014, which is around a Year quarter of total production, with a sales value of around $500 million Fig. 2 Output of cemented carbide products in China 1995 – 2014 (Fig. 4). Imports of cemented carbide products in China reached 1,508 mt in 2014. Value of cemented carbide production in China Cutting tool production 250 In 2014 cutting tool production in China was reported at 5,000 mt, 200 with output of cutting inserts for CNC machines reaching 93 million

150 pieces. Cemented carbide tools for mining reached 6,000 mt and wear (billion RMB) parts around 10,000 mt, wherein 100 bar material was 4,500 mt and hardfacing material some 1,310 mt. 50 The output of cemented carbide for

Sales income deep-processing and oil and gas

0 exploration reached 4,850 mt in 1995 2000 2005 2010 2014 2014. At the same time, the output Year of micro drill components was more than 500 million pieces and the Fig. 3 Sales income of cemented carbide production in China (billion RMB) output of solid cemented carbide tools for hole drilling/machining was around 26 million pieces. Fig. 5 Exports of cemented carbide from China compares the market share of the (tonnage and sales) main cemented carbide product Ton Million dollar groups in 2009 and 2014. According to the machine tool 7000 400 Export amount association, some 7.398 billion 6000 350 cutting tools were produced in China in 2013, representing an annual 5000 300 market worth more than RMB

4000 250 40 billion. Of this total cemented ([SRUWIRUHDUQLQJIRUHLJQFXUUHQF\ carbide tools made up around 45% 3000 200 of the market, with high speed steels at 53% and superhard tools at 0 150 2% (Fig. 6). Cemented carbide tools 2008 2010 2012 2014 accounted for around RMB 20 billion in sales of which CNC indexable Fig. 4 Exports of cemented carbide from China in tonnage and sales carbide inserts made up approxi- income 2008 – 2014 mately 50%.

Key players in China’s cemented carbide industry

Zhuzhou, in the Hunan Province, 2009 is considered to be the home of Steel bonded cemented carbide Other cemented carbide cemented carbide production in Cutting inserts 0.2% 13% China. Zhuzhou Cemented Carbide 21% Group Corp Ltd (ZCC) was one of China’s key projects in the nation’s ‘First Five-Year Plan’ and the company is, after more than fifty years of production, the country’s largest producer of cemented carbides and tungsten products Wear parts Cemented carbide with sales of almost RMB 6 billion 42% for mining in 2014. It is also home to significant 24% technology research efforts. In addition to the long established ZCC, the Zhuzhou region is today estimated to have almost 140 enterprises engaged in the 2014 production of cemented carbide Others and tungsten-base products. Most Cutting inserts 1% 23% of these enterprises are classed as small to medium size companies with around 22 having sales of over RMB 100 million. Some of the other cemented carbide producers in the region include Zhuzhou OKE, Zhuzhou Jinggong, Zhuzhou Jinwei, Zhuzhou Kingtal, Zhuzhou Seed, Wear parts Zhuzhou Tongyi, Zhuzhou Huarui, Cemented carbide 48% Zhuzhou Lizhou, Zhuzhou Jinding for mining 28% and many others. Zhuzhou OKE Cemented Carbide Co., Ltd, produces a range of NC inserts for high precision machining of special materials and also carbide Fig. 5 Comparison of market share of different cemented carbide product drill bits. In 2014 total output of groups in 2009 and 2014 cemented carbide increased 105% compared with that of 2009. At the same time the sales income increased 241% and the profit TOOL CONSUMPTION STRUCTURE (DOMESTIC) increased by a factor of 15. Seed Cemented Carbide Cemented Technology Co., Ltd., manufactures HSS tool carbide various deep well processing tools, 53% 45% high precision cemented carbide parts, machined cemented carbide parts such as non-standard inserts, tubes, rings and plates, integrated cemented carbide parts and composite parts of cemented carbide and other metal materials. In 2014 Diamond and exports accounted for over 70% of CBN tool 2% total income. Total output of cemented carbides in the Zhuzhou region was some Fig. 6 Breakdown of domestic cutting tool consumption

8,600 mt in 2014, having a sales value Recycling of cemented Product areas for China’s reported at RMB 11 billion, or 50% carbide and tungsten cemented carbide industry of China’s total cemented carbide scrap sales. The reason for the high sales CNC Indexable inserts value is that carbide inserts for Recycling of cemented carbide Indexable inserts for CNC cutting CNC machining are one of the main scrap is today an important element tools used in machining metals products in the Zhuzhou region and in in the availability of tungsten were first developed in Europe and 2014 output represented some 75% of carbide raw materials with the the United States in the 1970s. After all CNC inserts made in China. amount of carbide scrap recycled more than 40 years of development Significant Chinese cemented reaching an estimated 30% of and innovation, CNC inserts have carbide producers in other regions total carbide output. There are a become major market products in include: Xiamen Golden Egret Special number of companies involved in the the field of metal cutting. At present Alloy Co., Ltd, based in Xiamen, recycling industry and these include in Europe and the United States and which reported that total output of Shandong Linqu Wolong Cemented other developed countries, about cemented carbide in 2014 increased Carbide Co. Ltd., GEM Jingmen New 80% of inserts for metal cutting 185% compared with that of 2009. Material Co. Ltd., Xiamen Golden use hard alloy coating, diamond or CY Carbide MFG. Co., Ltd, founded Egret Special Alloy Co. Ltd., as well PCBN inserts. in 2003 in Jiangsu, manufactures as others in Qinghe Hubei, Wenzhou Whilst China was a rela- cemented carbide and tools such as Zhejiang, etc. The total recycling tive latecomer to the production saw blade tips, woodworking cutting amounts of cemented carbide of cemented carbide tools with blades, rods, cold heading dies, cold scrap reported by Linqu Wolong production of CNC carbide inserts punching dies and wire-drawing and GEM Jingmen in 2014 added first starting in the mid-1980s, dies. CY Carbide reported that export up to over 1,600 mt. The processes the country has since made great income accounted for 45% of total used for recycling cemented carbide strides in advancing its materials income in 2014. scrap include the zinc-process, technology and production know- KLT Carbide Co., Ltd., electrolysis, mechanical crushing how in order to compete with the headquartered in Chengdu, and high temperature calcination- high-end carbide tools product manufactures high precision sealing crushing. offered by producers in Europe, the rings, shaft sleeves, nozzles, valve The companies involved in the United States, Japan and Israel. cores, valve seats and drilling bits recycling of tungsten scrap include However, imported high-end cutting for oil exploration. In 2014 total Hunan Anhua, GEM Jingmen New tools, especially coated inserts output increased 436% compared Material Co. Ltd., Xiamen Golden and superhard PCBN inserts, still with that of 2009, with sales income Egret Special Alloy Co. Ltd. and account for around one-third of increasing by 187%. Exports increased others. The main process used for cutting tools used in China. by 233% and accounted for 64% of recycling tungsten scrap is gas Key characteristics of CNC total income. Table 1 lists the top ten oxidation-ion exchange and the total inserts produced in China compared Chinese cemented carbide producers recycling amount of tungsten scrap with traditional welded cutting according to sales income in 2014. reached around 10,000 mt in 2014. inserts include: • High efficiency • High reliability and long service Rank Company Sales income (thousand RMB) life 1 ZCC 5,980,770 • Chip breaking and ease of removal 2 GESAC 2,623,880 • High precision of inserts and 3 ZGCC 2,417,260 re-orientation precision 4 Zhangyuan Tungsten 2,025,000 • Mechanical clamping, index- 5 NCC 758,730 able, rapid replacing

6 Jiangxi Yaosheng 733,100 • Good size/dimensions consist- ency, enabling presetting 7 Shanghai Tool Works 653,310 These characteristics will be 8 Jiangsu Hetian Tech 469,580 important in the implementation 9 Jingmen Dewei-GEM 317,950 of one of China’s national develop- 10 Zhuzhou OKE 297,190 ment programmes, “High-end CNC machine and basic manufacturing Table 1 Top ten cemented carbide producers in China according to sales equipment”. The project specifies income in 2014 that by 2020, 80% of CNC machines

Fig. 7 CNC cemented carbide inserts and cutting tools made Fig. 8 Examples of diamond coated, PCBN and in China cermet superhard tools made in China

used for manufacturing in the Superhard materials problems of difficult-to-machine aerospace, automotive, ship and In recent decades tools made materials. It is expected that over power generation sectors must from superhard materials such 15 million superhard tool pieces will be produced domestically. From as natural and synthetic diamond, be produced in China by 2020. now until 2020 it is estimated that polycrystalline diamond (PCD) and production of CNC machines in polycrystalline cubic boron nitride PCB micro drill bit production China will increase by over 15% (PCBN) (Fig. 8) have been added to The global market for printed circuit annually. the cutting tool mix and currently board (PCB) carbide micro drill bits It is estimated that there are at make up around 2% of total sales used in the electronics industry was present twelve enterprises in China in China. Superhard tools have around 1.2 billion pieces in 2013 with producing indexable inserts from carbide and superhard materials according to International Stand- “Production of PCB drill bits is ards materials types P, K, M and expected to reach 1.6 billion pieces S, the latter for aerospace applications. These companies include by 2020 and China is expecting its Zhuzhou Diamond Cutting, Xiamen Golden Egret Special Alloy, Ganzhou market share to exceed 50%” Achteck, Zhuzhou OKE, Chengdu Bangpu, Zhuzhou Huarui and become indispensable for some China having around 40% market Jiangxi Jiangwu. Sales volume in machining applications such as share. Production of PCB drill bits is 2014 was estimated to be 93 million green machining, turning replacing expected to reach 1.6 billion pieces pieces and three newly built produc- grinding, milling replacing grinding, by 2020 and China is expecting its tion lines, with annual capacity machining of hard materials, high market share to exceed 50%. The of over 10 million pieces, began speed cutting and dry cutting. main foreign PCB micro drill bit production in 2013. Total annual Superhard material tools producers are Union Tool, Topoint production capacity of CNC inserts have also been widely applied in Technology, Kemmer Prazision and is said to be around 146 million machining of hardened steel, high HP Tec GmbH. The largest produc- pieces (Fig. 7). temperature alloys, die steels, tion enterprise in China is Shenzhen It is expected that by 2020 the all kinds of non-ferrous alloys, Jinzhou Seiko Technology with 0.23 annual production capacity of advanced composite materials billion pieces output in 2014. China‘s cemented carbide CNC and wood processing. The main The main development trends in inserts will reach more than advantages of superhard tools are cemented carbide PCB micro drill 300 million pieces, which can meet the good dimensional precision after bits are that of decreasing drill bit 50% of the demand of the domestic machining, greatly improved service diameters to around 0.1 mm and market, up from the present third. life of the tools and overcoming the below, as well as the production of

coated micro drill bits. Examples of PCB micro drill bits are shown in Figs. 9 and 10.

Carbide tools for engineering resources, mining and down hole drilling Both down hole drilling for oil and gas exploration and also mining/ quarrying depend greatly on cemented carbide and superhard Fig. 9 PCB carbide micro drill bits and milling cutters roller bits, etc. Carbide bits are also extensively used for civil engineering, tunnel construction, highway 0.02 mm diameter micro drill bit construction and maintenance and for the construction of railway infrastructure. Examples are given in Human hair Figs. 11 and 12. Micro drill Developing and drilling of oil and The drill diameter gas fields requires a substantial is equal to 1/3 of number of cemented carbide and the diameter of a diamond composite buttons, PDC human hair bits, roller bit tools and precision wear parts such as mechanical seals, bearings, bushings, nozzles, Fig. 10 PCB carbide micro drill bit having 0.02 mm diameter valve core seats, high-pressure plungers, electric submersible pump shaft sleeves and chasers for pipeline processing. At present the production output of cemented carbide buttons and compact alloy in China is over 3,500 mt. The main enterprises include Zhuzhou Cemented Carbide, Zigong Cemented Carbide, Xiamen Golden Egret, Suzhou Shreate, Chongyi Zhangyuan, Zhuzhou Kingtal, Hunan Century New Material and Zhuzhou JWE. The main enterprises for producing tools include Chengdu Deep, Kingdream, Changsha Heijin- Fig. 11 PDC bits for oil drilling (left), hole boring (centre) and rock coring (right) gang, LHS Rock Tools and Tianjin LILIN. Companies producing mining shield tools mainly include Zhuzhou Diamond Drilling, Liaocheng Tian- gong and Luoyang Jiujiu. Annual production capacities surpass 30,000 pieces. Enterprises producing road plane milling tools mainly include Xuzhou Kennametal and Zigong Cemented Carbide. It is estimated that ongoing exploration work for oil and gas will see an increase in demand for cemented Fig. 12 Different types of new hobbing tools (TBM hob, overbreak hob, carbide drill tools and precision internal pressurized hob) and inserted cutter ring produced by Zhuzhou carbide wear parts with sales to this Cemented Carbide sector in China forecast to exceed

Fig. 13 Solid cemented carbide milling cutters Fig. 14 Solid cemented carbide twist drill bits

RMB 10 billion by 2020 with about cutter body has also been reduced exploration, minerals, etc. one-third for exports. It is also and removable bits now offer longer This will require research into: estimated that domestic production tool life whilst eliminating the need advanced hard materials and tools, of PDC bits will exceed 60,000 pieces for re-sharpening. It is estimated forming of complex cemented carbide by 2020. The market for carbide tools that sales of solid cemented carbide composite parts, densification and for mining shield tools is forecast drill bits in China will exceed 40 sintering, multilayer nano composite to exceed RMB 2 billion by 2020 and million pieces in 2020. coating and grain orientation control, carbide tools used in road building gradient composite material, and construction will be around RMB in-service behaviour and performance 0.8 billion by the same year. Technology innovation for characterisation. There will also be further growth the need to develop process tech- Solid carbide drill bits nology for hard materials having high Another market sector which has China’s cemented carbide industry purity, ultrafine and nanostructures, seen sustained growth for cemented acknowledges that although great super coarse and complete crystal- carbides tools is the production of strides have been made in recent lisation structure, gradient structure, solid cemented carbide drill bits, decades at research centres such inhomogeneous composite struc- milling cutter bodies and remov- as the Key State Laboratory of ture, cemented carbide and diamond able drill bits with a growing choice Cemented Carbide, the Key State composite. of removable work pieces and also Laboratory of Powder Metal- Hard wear and corrosion resistant CVD and PVD coated drill bits (Figs. lurgy and the National Tungsten materials should be developed as 13 and 14). Major Chinese enter- Materials Engineering Technology well as steel matrix composites, prises involved in this sector include Zhuzhou Diamond Cutting, Shanghai “It is estimated that sales of solid Tool Work, Xiamen Golden Egret Special, Harbin Tool Works and cemented carbide drill bits in China Jiangsu Changzhou Xixiashu. In addition to steel materials for will exceed 40 million pieces in 2020” the workpiece holder, special bits for hard-to-machine materials such Centre, more work needs to be done polycrystalline material composites, as titanium alloy, high temperature urgently to meet the increasing high hardness and high tough- alloys and composite materials for demand for improved efficiency ness functional structures and hard aerospace have also been developed. cemented carbide products. This will material finishing as well as surface Advances in removable cemented particularly be the case for ‘high- spraying. High-end indexable insert carbide bits have resulted in a end’ CNC carbide tools needed for designs, structural designs and the reduction in the time to change the advanced CNC machining equip- wider application of tools should be cutter body, resulting in reduced tool ment in sectors such as automotive, promoted which include CNC tool management costs. The amount aerospace, rail transportation, ship inserts, superhard tools, precision of hard alloy materials used in the building, oil and gas and minerals wear-resistant sealing parts, high

It will also be producing in large quantities military fighter jets and helicopter gunships. It is estimated that the global aerospace sector accounts for around 12% of the cutting tool market.

Outlook for China’s cemented carbide industry in 2020 It is estimated that in 2020 production output of China‘s cemented carbide Fig. 15 Key growth is expected in China’s aerospace sector, helped by the industry will be 33,000 mt with sales introduction of domestically manufactured aircraft such as the ARJ21 income around RMB 50 billion. developed by state owned COMAC and set to enter service in Spring 2016 Export of cemented carbides is expected to exceed 10,000 mt, with speed wire rolls and composite rolls, for around 50% of total income, but foreign exchange earning these structural parts for nuclear shielding, the joint-stock and private enterprises exports in excess of US $1 billion. excavating drills, coal mining tools have proved themselves to be more High-end carbide NC inserts will and road plane milling tools. productive and profitable. State- exceed 300 million pieces. Solid These ambitions are supported owned enterprises for cemented cemented carbide tools will exceed by China’s ‘Made in China 2025’ carbide production must, therefore, 40 million pieces. PCB drill bits initiative, a policy similar to Germany’s carry out reforms which will greatly will be close to 800 million pieces. Industry 4.0 plan for intelligent manu- change the capital structure and Operating income of carbide bits facturing. The aim for China is that operational mechanisms of the and structural parts for oil and gas future production should be innova- enterprises concerned and which will exploration and mining, transportation-driven in order to transform the lead to the mergers and acquisitions tion infrastructure, precision wear country from a ‘large’ manufacturing of numerous joint-stock enterprises parts and cemented carbide drilling state into a ‘great power’ manufac- and private enterprises. The cemented tools will exceed RMB 1.5 billion. It turing state. carbide industry in China will also is estimated that more than thirty The focus of Made in China 2025 benefit from new and innovative busi- cemented carbide enterprises will will be on a number of areas such ness start-ups. be listed on the stock exchange. If as novel information technology, Future growth in the cemented estimates are correct, China can look numerical control machines and carbide and superhard materials forward to maintaining a powerful robots, equipment for aeronautics and sectors will of course ultimately cemented carbide industry. astronautics, equipment for ocean depend on the growth of the Chinese engineering, high tech watercraft, economy. The country aims to achieve advanced equipment for rail traffic, an annual economic growth rate of Author energy-saving and new energy vehi- around 7% in the period up to 2020. Zhongjian Zhang is President of the cles, electric power equipment, new In 2014 a total of almost 24 million Cemented Carbide Branch of China materials, biomedical and medical vehicles were produced in China, Tungsten Industry Association. He devices, agricultural machinery and accounting for a quarter of the world is also a Director of the State Key equipment. The policy includes five total. This number is expected to rise Laboratory of Cemented Carbide modules when applied to equipment to over 25 million in 2015, an increase and Deputy Chief of the Tungsten manufacturing. These include mate- of 7% and by 2020 total vehicle Department at China Minmetals rials, process and equipment, works, production is estimated to reach 30 Non-Ferrous Metals Co. Ltd, China transportation and selling. These million, maintaining the country’s are independent modules with each position as the world’s largest vehicle Zhongjian Zhang having a software system, communi- producer. The annual demand for CNC No.288, cation system, sensor system, auto- inserts and cutting tools just for the Diamond Road, matic detection and control system. automotive sector alone is expected to Zhuzhou, There will also be a need over the exceed 300 million pieces by 2020. Hunan, next five years to undertake deep Another key growth sector is China industry reforms and to upgrade China’s aeronautical industry. The Email: [email protected] industry including the cemented country has started mass producing carbide sector. Sales of the state- commercial aircraft and series owned enterprises currently account production of large passenger aircraft.

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The event of the year for anyone involved in 3D manufacturing

Entering its 26th year, SME’s RAPID event plays a vital role in defining additive manufacturing. It is where manufacturers and product designers come to explore the newest technologies, product introductions, and materials in additive manufacturing and 3D scanning. No other event provides such a comprehensive display of 3D technology, expertise, and innovation in one place.

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may 16-19, 2016 | exhibits may 17-19 orange county convention center | west building orlando, fl

Hagen 2015: Advances in metal powder technologies at Germany’s annual PM symposium The event of the year for anyone involved in 3D manufacturing The 34th Hagen Symposium, organised by Germany’s Fachverband Pulvermetallurgie, was held in Hagen, Germany, on November 26-27, 2015. The annual meeting for the German-speaking PM community attracted Entering its 26th year, SME’s RAPID event plays a more than 200 delegates and the accompanying exhibition included some 62 vital role in defining additive manufacturing. It is where exhibitors. Dr Georg Schlieper reports on a number of presentations focused manufacturers and product designers come to explore on the hardmetal industry as well as a presentation that looks at the potential the newest technologies, product introductions, and of thermoelectric materials. A novel sintered soft magnetic composite materials in additive manufacturing and 3D scanning. material, that combines the advantages of SMC with the strength of sintered No other event provides such a comprehensive display of PM materials, is also discussed. 3D technology, expertise, and innovation in one place.

Visit Historical development material consisting of hard and key requirement for the production of hardmetals and trend wear resistant tungsten carbide of high-performance hardmetal tools (WC) embedded in a metallic binder for cutting metal, wood or rock, wear rapid3Devent.com produced by towards finer hardmetal phase, usually cobalt (Co). The parts and metal forming tools. to learn more grades availability of high quality tungsten The current world market for As is the tradition at the Hagen carbide powders has always been a hardmetal products is estimated Symposium, the meeting opened with a presentation by the winner of the Fachverband Pulvermetallurgie’s COMPANYB prestigious Skaupy Prize. This year’s EVENT NAME® is produced by SME recipient was Professor Wolf-Dieter Schubert, Technische Universität Wien, Austria, (Fig. 1) who was introduced in a laudatory speech by Burghard Zeiler, Secretary General of 3D PRINTING EVENT rapid3Devent.com the International Tungsten Industry Association. Schubert began his may 16-19, 2016 | exhibits may 17-19 Skaupy Lecture with a review of the orange county convention center | west building history of hardmetal materials, then orlando, fl discussed the trend towards finer hardmetal grades due to the growing demand for harder materials with higher strength and toughness. Hardmetal, also known as Fig. 1 Wolf-Dieter Schubert (centre right) receives the Skaupy Prize from cemented carbide, is a composite Burghard Zeiler (left), Hans Kolaska (centre left) and Herbert Danninger (right)

at 75,000 tons per annum. Besides the impressive growth in size, the structure of the hardmetal market has also undergone fundamental changes. From standard WC powders with particle sizes of 1-5 µm in the past there has been a clear trend towards finer powders and today Ultra fine grain Micro grain submicron powders are predominant, Coarse grain with a market share of approximately 55%. Coarser WC grades (> 5 µm) contribute roughly 12 % of the world Transverse rupture strength (MPa) strength rupture Transverse market. The submicron powders Contour data: late 1980s are further divided into micro grain Filled data: recent values (average particle size 0.5 –1 µm, 85% Co content (%) share), ultra-fine grain (0.2 – 0.5 µm, 15%) and nanocrystalline powders Fig. 2 Strength of hardmetal grades (Courtesy H. Westermann) [1] (< 0.2 µm, < 1%). The reason for the trend towards finer hardmetal grades is the growing demand for harder materials with higher strength and toughness. This was achieved by a substantial reduction of the number of defects in the hardmetal such as residual porosity, local grain growth and precipitations. The transverse rupture strength of various hardmetal grades in the late 1980s and today is depicted in Fig. 2. A comparison shows that, in the past, the fine grained grades particularly exhibited clearly lower strengths than the coarse grained hardmetals. Even after eliminating the residual porosity by Hot Isostatic Pressing (HIP) there Fig. 3 Water jet cutter (left) and the nanocrystalline microstructure of was still local grain growth that could ‘binderless’ hardmetal (Courtesy Ceratizit) [1] not be avoided. The high strength micro grain and ultra-fine grades are based on an improved powder production technology and the use of grain growth inhibitors such as vanadium carbide (VC). Beginning in the 1990s, advanced Physical Vapour Deposition (PVD) coating technologies provided an additional significant contribution to the success of hardmetal tools for cutting applications. The combina- tion of micro grain hardmetal with high strength and PVD coating under compressive stress has proven to be a reliable and efficient concept for the cutting tool industry. Optimised geometries and reduced surface roughness at the cutting edge led to substantial improvements of cutting Fig. 4 Deep drill for printed circuit boards (Courtesy MMC Hitachi Tool) [1] tools with adaptation to the applica-

tion. According to Schubert, further order to save raw material. Innovative water jet treatment with an abrasive significant progress can be expected compaction techniques are used to medium for the modification of the in this sector. produce cutting edge geometries that cutting edge micro geometry. This In his comprehensive review, were previously impossible to realise. process is flexible and can be used Wolf-Dieter Schubert outlined the either to generate complex cutting most important applications of edge shapes or to improve coated micro grain hardmetals and the Current trends in cutting cutting edges. The rounding of the progress made since the 1980s. tools and material cutting edge is achieved in a system About 60% of these grades are used developments where the required movements are for metal cutting tools, usually with performed by an industrial robot a PVD coating of 1 – 5 µm thickness Another contribution on the subject (Fig. 5). The tool is manipulated consisting of TiAlN, AlCrN or DLC of cutting tools was presented by freely under a fixed nozzle and the (diamond-like carbon). Between 1985 Professor Dirk Biermann, Technical edge preparation aims at eliminating and 2009 the cutting performance University Dortmund, Germany. He microscopic defects in the cutting of a hardmetal roughing cutter as stressed the point that technically edge that originate from the grinding expressed by the volume of material advanced solutions in the cutting process. In addition, the cutting edge removed per time unit has been tool sector should not only consider profile is optimised for the respective increased by a factor of 15 due to the cutting tool material, coating machining process. This concept improved hardmetal quality, coating and cutting edge geometry. Wear parts requiring high “This concept enables the modification strength are increasingly made from of even limited areas of a cutting micro grain and ultra-fine hardmetal. With approximately 18% share they edge in the desired way and creates sit in second place. Applications are extremely diverse and include complex cutting edge shapes” classical wear parts such as wire drawing dies, cutting blades, sealing and cutting edge geometry, but enables the modification of even rings, milling cutters (coated) and also the material properties of limited areas of a cutting edge in the many more. So-called ‘binderless’ the work piece and the processing desired way and creates complex hardmetals, which, with a hard- parameters such as cutting speed, cutting edge shapes. ness of 2800 HV10, have the highest feed rate, cutting depth, mechanical Besides newly manufactured hardness of hardmetals, are used for and thermal stresses, lubricating tools, re-sharpened machining tools water jet cutting (Fig. 3). and cooling media. Not only are the are also improved by the water jet Tools for the electronics industry individual aspects relevant, but also treatment. When twist drills are are another important sector with the interaction of many of these re-sharpened, new main cutting a share of roughly 10% of the total parameters should be considered. edges and a new cross-cutting market for submicron hardmetals. Biermann discussed the benefit of edge are generated. As microscopic Drills and milling cutters for printed circuit boards are produced in huge quantities. Drills can have diameters down to 20 µm, deep drills down to 50 µm and the depth-to-diameter ratio can be up to 100 (Fig. 4). Indexable inserts for metal cutting applications represent roughly 8% of the submicron market. This market continues to grow as submicron powders with improved compacting and sintering properties are available. Indexable inserts made from micro grain hardmetal grades with PVD coatings are used for drilling, milling and partly even for turning. All-purpose tools enable a broad range of applications for many metal alloys and there is a clear trend Fig. 5 Robotic arm with twist drill in a water jet spray unit (Courtesy D to reduce the size of the inserts in Biermann) [2]

Fig. 6 SEM image of TiN/TiCN/AlTiN coating (courtesy R Fig. 7 HR-TEM image of nano layers in HR-CVD AlTiN Pitonak) [3] (courtesy R Pitonak) [3]

defects are again introduced into tion SEM and TEM, however, revealed Ultrasonic fatigue testing of the region of the cutting edge by that the entire coating was composed hardmetals regrinding and the shape of the of micro crystals (~100 nm) that cutting edge after regrinding is not themselves exhibited a unique Herbert Danninger, Professor at the adapted to the cutting process, a lamellar substructure (Fig. 7). Technische Universität Wien, Austria, rounding of the cutting edge is also Lamellae occurred at different and Chairman of Fachverband required here. Usually regrinding positions in the coating and their Pulvermetallurgie, presented results affects only the flank of the cutting respective orientation was uncorre- of a joint research project sponsored tool and the original coating is still lated. In addition, the TEM analyses by major players in the European present on the rake face. showed that with minimal tipping hardmetal industry. The project Reinhard Pitonak of Boehlerit new surfaces with periodic nano title “Ultrasonic Fatigue Testing GmbH, Austria, reported on innova- layers appeared and the previously of Hardmetals (UFTH)” indicates tive multilayer coatings for cutting observed structures disappeared. that the objective was to study the tools deposited by Highly Reac- This suggests that the entire coating fatigue behaviour of hardmetal under tive Chemical Vapour Deposition consists of highly organised lamellar high frequency loading. The high (HR-CVD). When these coatings were substructures that can be clearly frequency allows the extension of investigated with optical and electron distinguished from one another. This the fatigue tests, which for practical microscopes, they exhibited a rather nano layered structure has previously reasons are usually limited to 10 common structure with columnar been described for PVD coatings, but megacycles, into the gigacycle range. crystal growth (Fig. 6). A more according to Pitonak it is entirely new According to Danninger, testing detailed analysis using high resolu- for CVD coatings. in the gigacycle range offers the chance to work out the mechanisms of fatigue and crack initiation in particular clarity. Generally, one can differentiate between various types of material failure, especially in fatigue. Structure controlled There is ‘structure controlled’ and crack initiation ‘defect controlled’ crack initiation Defect controlled (and for real components, geometric crack initiation Fatigue strength effects such as notches, scratches etc. should be considered as a third type of crack initiation). Structure Delta Ktheff Critical defect controlled crack initiation starts No damage at one or more structural features

Cyclic stress amplitude (log) stress Cyclic size which are abundant in the material. An example is the relatively coarse carbide size in chromium alloyed cold Defect size a (logarithmic) working steel of type 1.2379 (AISI D2). The probability of a crack being Fig. 8 Kitagawa-Takahashi diagram (after H Danninger) [4] initiated at such a carbide is very high

and consequently the scattering of individual values is small. The alternative is defect controlled crack initiation. In this case the crack Strain Resonator starts from structural defects which Adapter gauge Cooling circuit are very rare; typical examples are oxide, carbide or nitride inclusions 20kHz in high purity steel grades such as Generator roller bearing or spring steels, or slag inclusions in powder metallurgy Acoustic horn Sample tool steels. This type of material failure is comparable to that of PC high-performance ceramics in static tests where generally the largest existing defect in the loaded volume Fig. 9 Test rig for gigacycle fatigue testing (Courtesy H Danninger) [4] determines the strength. Danninger concludes that even metallic materials in gigacycle fatigue may show ‘ceramic behaviour’. The microstructure versus defect controlled fracture behaviour is evaluated, for example, with a Kitagawa-Takahashi diagram (Fig. 8). The fatigue strength is plotted against the defect size in a double Internal defect logarithmic diagram. Up to a certain “fisheye fracture” size of defects, these are irrelevant for the failure; the strength is defined by the structure. At a certain critical defect radius, the crack starts from the largest defect in the loaded amplitude Δ σ/2 [MPa] stress Cyclic volume. The fatigue strength of the Cycles to fracture, Nf material is then lower, the larger the defect is. The characteristics required Fig. 10 Typical SN curve for hardmetal (courtesy H Danninger) [4] for this plot are the fatigue strength of the defect-free material (or a material with subcritical defects) probabilities were calculated from cubic lattice, no real fatigue limit and the ‘effective threshold stress the results. Fig. 10 shows a typical could be found for PM steels. intensity factor’ ΔKth eff which is a SN curve. As can be seen, the material characteristic for the crack dispersion of the individual values The potential of is small, which is surprising given propagation. Thus, the Kitagawa- thermoelectric materials Takahashi diagram requires only the low toughness of cemented fatigue-related data. carbides. This can be interpreted Thomas Weissgärber of the The test rig used for fatigue as an indication of a structure Fraunhofer Institute IFAM in Dresden, testing is schematically shown in controlled failure and a defect-free Germany, reported on the present Fig. 9. The load is introduced by a microstructure, writes Danninger. status and potential of thermo- 20 kHz electrical signal which is Also apparent is the fact that, at electric materials. The distribution converted to a symmetrical tension- least up to the maximum applied load of charge carriers in a material is compression loading (R = -1) and and up to a number of 10E+10 cycles, affected by temperature gradients in amplified by an acoustic horn. The no real fatigue limit exists. The such a way that an electrical voltage load amplitude is indirectly measured curves continue to decline at higher arises between regions of different by a strain gauge on the adapter N values in a slightly concave curve. temperature. piece and the heat generated by the This behaviour is consistent with the This phenomenon, first described high test frequency is removed by a results found for other materials in in 1821, is referred to after its discov- cooling circuit. the gigacycle range, such as high- erer as the Seebeck Effect. Mobile As common in fatigue testing, alloy steels or sintered steels. In charge carriers in warm areas have several tests were run at a contrast to the traditional conception a higher kinetic energy and diffuse certain stress level and the failure for steels having a body-centred faster than the charge carriers in

Heat input a flow of electricity is generated. A thermoelectric module contains Hot side (isolator) many of these basic units which are electrically connected in series and thermally in parallel. For a continuous flow of electricity the tempera- Metal contacts p side n side ture gradient must be maintained, that is, on the hot side, heat must be supplied and, on the cold side, heat must be dissipated. The module does not contain any moving parts and is Cold side (isolator) Heat dissipation free from wear. The efficiency of thermoelectric materials for transforming heat to electrical energy is defined by the Fig. 11 Basic unit of a thermoelectric module (Courtesy T Weissgärber) [5] efficiency coefficientzT . A selection of p-type and n-type thermoelec- cold areas, so more charge carriers voids. Depending on the type of tric materials and their efficiency move from warm areas to cold areas charge carrier that accumulates at coefficients is given in Fig. 12 as a than vice versa. As a result, charge the cold side, either a positive charge, function of the temperature. Many carriers accumulate in the cold areas i.e. voids, or a negative charge, i.e. of these materials are intermetallic and an electrical potential difference electrons, researchers distinguish compounds of tellurium and another between the areas is obtained which between p-type and n-type ther- metal. High temperature materials is proportional to the temperature moelectric materials. Materials with efficiency coefficients between difference. The electrostatic repulsion researchers at IFAM are developing 1 and 1.5 are available, but efficiency of equal charges, however, drives technical solutions with the objective coefficients above 1.5 are still very the charge carriers back against the of using the waste heat of technical rare. Modules having sufficient temperature gradient in the direction processes or motor vehicles for the performance and reliability are of the warm area. After reaching the generation of electrical power. under development. In order to be steady state between these effects The basic design of a thermo- competitive in the field of waste heat there is no forward current of charge electric module is shown in Fig. 11. utilisation, Weissgärber says, better carriers in the material. It consists of a n-type and a p-type thermoelectric materials with effi- In metals the mobility of charge material. The two pieces are electri- ciency coefficients between 1.5 and carriers is so high that the Seebeck cally connected with each other on 3 have to be developed. Besides the Effect cannot be exploited technically, one side. The temperature gradient thermoelectric efficiency, the toxicity, but certain semiconducting materials between the hot and cold sides availability and cost must also be exhibit a more pronounced Seebeck leads to the formation of an elec- considered. Effect. Negative charge carriers trical voltage in both materials. If According to Weissgärber, tellu- are electrons and positive charge an electrical load is connected to rides are usually manufactured by carriers are missing electrons, i.e. the two legs to form a closed circuit, casting, but Powder Metallurgy can

Fig. 12 Thermoelectric materials and their efficiency coefficients (as published in paper by LaLonde, A D et al. Lead telluride alloy thermoelectrics. Materials Today, 14, 2011, 526-536) [5]

be applied to improve the mechanical properties with equal thermoelectric Si properties. In general, PM offers high quality and homogeneous materials Fe Fe as well as materials which can only be prepared by PM (silicides are one example). The PM process described Fe-Si by Weissgärber for the most widely Gradient Fe used thermoelectric material bismuth Fe Fe telluride Bi2Te3 involves atomising a melt of the desired composition, high energy milling and hot pressing or spark plasma sintering SPS to Fig. 13 Schematic concept for SSC material (Courtesy J Burghaus) [6] consolidate the powder. Melt spinning and SPS can be used to produce nano structured materials. 1000 C für 30 min 50 µm 1200 C für 30 min 50 µm The utilisation of waste heat by means of thermoelectric modules is an interesting technology for the automotive industry that can be utilised to meet the demanding CO2 limits in the future. The potential to improve the energy efficiency of industrial processes is also of great Fe Fe Fe interest. Progress has been made in Fe recent years in the development of FexSiy- thermoelectric materials for applica- Beschichtung Fe Si x y FexSiy tions at higher temperatures, but further research is necessary before this technology can be exploited Sintering temperature commercially. Fig. 14 Sintering of Si coated iron powder (Courtesy J Burghaus) [6]

Sintered soft magnetic A new material concept was should be limited so that an iron composites combine the presented called sintered soft silicide phase Fe3Si is formed at the advantages of SMC with magnetic composites (SSC) because particle boundaries (Fig. 13). In the the strength of sintered PM it combines the advantages of SMC boundary phase, a bulk electrical materials with the strength of sintered PM resistivity of up to 2 μΩm can be materials. The basis for the new achieved. Such a high resistivity is An innovative concept for soft material concept is the conventional not realised in a homogenous iron- magnetic PM materials was soft magnetic iron-silicon alloy. In silicon alloy. In addition, iron silicide presented by Jens Burghaus of sintered iron-silicon alloys, iron exhibits a ferromagnetic atomic order Robert Bosch GmbH, Stuttgart. is used due to its favourable soft which means a reduced air gap as Currently, soft magnetic PM materials magnetic properties: high satura- compared to conventional systems. are either composites made up of tion of approx. 2.15 T, high maximum Researchers aimed at a high density iron powder and a polymeric binder permeability. Silicon has a positive and a sound sintered structure or sintered alloys. Soft Magnetic effect on the electrical resistance, that provides sufficient mechanical Composites (SMC) are characterised maximum permeability and coercive strength and good magnetic proper- by low eddy current losses, which force. ties. is advantageous for applications In contrast to the traditional, Attempts with a mix of iron in alternating magnetic fields, but homogeneous sintered material the powder, an iron-silicon master alloy the mechanical strength is limited. new concept aims at a defined, inho- for a total silicon content of 3% Si Sintered soft magnetic materials mogeneous microstructure which and lubricant, then compacted at have a higher strength, but also high is composed of a high-resistance 800 MPa and sintered at tempera- eddy current losses. This is why the iron-silicon phase that completely tures between 1050°C and 1200°C, requirements for many soft magnetic envelops the soft magnetic iron failed because the formation of sinter applications are not yet met by PM particles. The interdiffusion between contacts required a temperature of materials. silicon and iron during sintering 1200°C and the diffusion of silicon

Sintered Coated powder Höganäs 1P References Material powder mix sintered Somaloy 500 [1] SKAUPY-Vortrag: Ultrafeinstkorn- 1100°C, 1000°C, Robert Bosch GmbH, Heat treatment 30 min (N ) 30 min (N ) CR/ARM3 hartmetalle - Vom Pulver zum 2 2 Werkzeug, Prof. Dr. W.-D. Schubert, Density [g/cm³] 6.56 / 6.83* 6.88 7.48 Austria, as presented at Hagen Resistivity [µΩm] 0.76 / 0.75* 1.38 58 Symposium 2015, FPM, Germany

Induction @ 50 kA/m [T] 1.40 / 1.55* 1.56 1.92 [2] Aktuelle Trends in der Schneidstoff- und Werkzeugent- Max permeability 271 / 451* 433 504 wicklung – Herausforderungen Coercive force [A/m] 255 / 243* 265 310 und Lösungen, Prof. Dr.-Ing. Dirk Biermann, Germany, as presented Bending strength [MPa] 61 / 80* 119 42 at Hagen Symposium 2015, FPM, Values marked with an asterisk (*) are for repressed samples. Germany Table 1 Comparison of different soft magnetic PM materials [6] [3] Neuartige TiAlN-Beschichtung mit spezieller Nanostruktur, abge- in iron at this temperature was so silicon phase of 2 µm thickness and schieden mittels HR MTCVD, Dipl.- fast that a homogeneous alloy was the coating was still intact, at 1200°C Ing. Dr. Reinhard Pitonak, Austria, formed. In the next step, 1% copper it has been completely dissolved in as presented at Hagen Symposium was added with the intention of the matrix (Fig. 14). The total silicon 2015, FPM, Germany forming a transient liquid phase with content was 2%. [4] Ermüdung von Hartmetallen im a low melting copper-silicon eutectic A comparison of the two newly Gigacycle-Bereich - Prüftechnik during sintering that would enhance developed SSC materials with a und Werkstoffverhalten, Univ.-Prof. the sintering process. A compromise commercial SMC is given in Table 1. Dr. Herbert Danninger, Austria, as between magnetic properties and The concept of silicon-rich particle presented at Hagen Symposium strength, although not fully satis- boundaries appears feasible, but 2015, FPM, Germany factory, was achieved at a sintering further improvement is still required temperature of 1100°C, but the before this concept can be commer- [5] Thermoelektrische Werkstoffe electrical resistivity was too low for cialised. Above all, the density must und Generatoren - aktueller Entwick- AC applications. be increased in order to further lungsstand und zukünftige Potenziale Finally the iron powder particles enhance both the mechanical and für die Abwärmenutzung, Dr.-Ing. were coated with a thin iron-silicon magnetic properties. Thomas Weißgärber, Germany, as phase by a treatment in a fluid bed presented at Hagen Symposium 2015, FPM, Germany reactor with a reactive silane gas Author SiH4. The coated powder was mixed [6] Gesinterte weichmagnetische with lubricant and compacted, then Dr Georg Schlieper Verbundwerkstoffe: ein neues Werk- sintered at temperatures between Gammatec Engineering GmbH stoffkonzept, Dr. Jens Burghaus, 1000°C and 1200°C. The microstruc- Mermbacher Strasse 28 Germany, as presented at Hagen ture after sintering at 1000°C showed D-42477 Radevormwald, Symposium 2015, FPM, Germany that the powder particles had been Germany completely coated with an iron- Email: [email protected]

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Safety in the PM industry: Steps in reducing the risk of fire and explosion with metal powder dusts

A session on combustible dusts at POWDERMET2015, held in San Diego, USA, May 17-20, 2015, included two papers which assessed the potential risks with metal dusts and, perhaps more importantly, provided guidance on mitigation strategies to avoid these risks. Dr David Whittaker reports for Powder Metallurgy Review on the papers from this session.

The potential for creating pyrophoric gies prescribed in the USA by the volume ratio of a combustible dust fires or even explosions with finely National Fire Protection Association’s that differentiates it from a bulk divided dusts of highly combustible NFPA 484 Standard for Combustible combustible solid. The combustion materials, such as in flour milling or Metals and related standards [1]. rate of bulk solids is limited by the sugar refining, is widely recognised. The popular perception is that surface area of the solid in contact However, a number of incidents metals do not burn, but, according with the oxidiser (air) and so, as the over the years have concentrated to NFPA 484, “any metal in a fine particle size of a material decreases, the minds of both powder makers enough form can be combustible the specific surface area increases and PM parts manufacturers on the and/or explosible”. It is the small and combustion rate per mass of possibility of encountering similar particle size or large surface area to material increases. problems with metal powders. Consequently, the conference programme at POWDERMET2015, included a session entitled “Combus- tible Dusts” that included two papers on the subject.

Preventing fire and explosion of metal dust The first of these papers was by Alfonso Ibarreta and Timothy Myers of Exponent, USA. The paper provided an overview of combustible metal Fig. 1 Analogy of how the rate of combustion of wood increases as the particle dust hazards and mitigation strate- size decreases (after Eckhoff) [1]

compatible with traditional NFPA areas of guidance: suppression agents. For Hazard Analysis Particle size separation instance, many combustible Building construction Mixers and blenders metals react with water and so water sprinkler automatic fire Building explosion venting Dryers suppression is not effective. Equipment explosion protection Dust collection equipment • Even extinguishing agents Equipment isolation Fire protection designed for combustible metals can be dangerous to deploy Bulk storage Housekeeping because of risks related to Material transfer systems Management of change further dust dispersion. Size reduction operations Control of ignition sources • Explosion suppression and isolation system design is Segregation, separation, or Employee training, inspection, and complicated because of the high detachment of dust handling and maintenance combustion temperatures and processing areas KSt values. Table 1 NFPA combustible dust standards, including NFPA 484, cover a wide • Combustible metal dusts can range of subjects create an exothermic thermite reaction with oxides of other This concept is illustrated through handling processes, unintentional metals and so they should not be the analogy shown in Fig. 1. In this releases from equipment or from processed or conveyed in equip- scenario a log of wood is difficult to accumulations in a facility. ment used for other metals. ignite and burns relatively slowly; The first four elements are suffi- • Combustible metal dusts are however, if the log is chopped into cient to create a flash fire, but, for an electrically conductive and kindling it is easier to ignite and explosion, some degree of confine- therefore the presence of burns more rapidly. In the extreme, if ment is also needed. Confinement even small quantities of dust the log is ground up into a fine dust can be caused by the outer shell of can cause shorts in electrical equipment.

“The first four elements are The NFPA 484 Standard describes sufficient to create a flash fire, but, explosion and fire prevention and mitigation methods and states for an explosion, some degree of requirements to prevent the confinement is also needed” occurrence of ignitable dust clouds in the presence of ignition sources. The areas of guidance in the standard and dispersed in air, it is much easier equipment, the walls of a building (Table 1) are very wide-ranging and to ignite and burns very rapidly. A or by the presence of a heavily so the authors chose to restrict flame propagating through a cloud congested area. themselves to identifying examples of fine wood dust dispersed in air Combustible metal dusts can of methods used by facilities to deal is, in some ways, similar to a flame present unique challenges compared with common hazards. propagating through a mixture of a to more traditional organic dusts and Requirements in the standard flammable gas or vapour and air. the paper listed these hazards as: focus on keeping combustible The authors identified five • Some combustible metal dusts dusts and powders inside process elements needed to create a dust can burn at very high tempera- equipment and minimising dust explosion: combustible dust, an tures (up to 8,000°F). clouds and accumulations. These oxidiser, an ignition source, a issues can be addressed by multiple dispersion of the dust and confine- • Some combustible metals can methods: designing and maintaining ment. Oxygen in the air is the most produce very rapid pressure rises equipment to be dust tight, operating common oxidiser, although other during a deflagration. Aluminium equipment at negative pressure, gases can act as oxidisers, with and magnesium powders, for using dust collection at points some metals reacting with halogens instance, have very high values of of dust generation and frequent the deflagration index, K t. or carbon dioxide. Ignition sources S housekeeping to limit accumulations. include static electricity, sparks from • The standardisation of fire A variety of requirements address electrical equipment, hot surfaces, suppression systems for metal the control of the following ignition frictional heating and open flames. dusts is challenging, because sources: sparks (friction, electrical, Dispersion of dust may occur from a number of metals are not static electrical), grounding and

bonding, hot surfaces, hot work, open flames, heating systems, slipping belts, bearings and electrical equipment. Explosion protection of equipment can be broken down into two sub-sets, explosion prevention and explosion mitigation. Explosion prevention methods include oxidant concentration reduction (inerting), reduction of combustible dust concentration and dilution with a non-combustible dust. Explosion mitigation methods include explosion venting, explosion pressure Fig. 2 The Rembe Q-Rohr-3-6T-AL [2] containment, explosion suppression and explosion isolation.

Protective measures against fire and explosion of metal dusts

The second paper in the session was from Gerd P Mayer, Eric Finley and Helen Sztarkman of Rembe Inc., USA, and addressed protective measures against fire and explosion of metal dusts and the “peculiarities” of their applicability [2]. In a general introduction, the authors spelled out Fig. 3 Flame length of an explosion with aluminium dust [2] the three major considerations in explosion protection. The first consideration was defined as explosion prevention. Explosion prevention strategies comprise suspending of highly combustible process media in oil to avoid any possible reaction with oxygen, conditioning (transferring a combustible substance into a non-combustible one) or blanketing with an inert gas. While it is an attractive strategy in an ideal world, the authors counselled that, in real processes, the applicability of Fig. 4 Explosion of aluminium dust with the Rembe Q-Rohr-3-6T-AL installed explosion prevention methods is (compare with Fig. 3) [2] limited. The second consideration was Hence, there is a need for the If an enclosure is inside the building, therefore the avoidance of ignition third consideration, mitigation of the flameless indoor venting systems sources. A similar range of potential effects of an explosion. Various NFPA represent an option or chemical sources to that identified in the standards were quoted as defining suppression might be used. previous paper was discussed, but proper mitigation techniques for In addition to the venting, it was concluded that preventing processes that have combustible dust interconnected enclosures must be ignition sources with 100% certainty risks. For example, enclosures are equipped with devices designed to is difficult and costly and is made commonly fitted with properly sized isolate an explosion so that it does even more difficult because of the explosion panels if the enclosures are not propagate, Passive flap valves uncontrollable human factor. outside or close to an external wall. and active quench valve devices are

are very feasible options in many metal dust applications. However, recirculation of air is strictly prohibited. Where dust collectors are installed outdoors, explosion panels are an excellent option for venting an explosion, but care must be taken that the vent is directing the potential explosion away from people, buildings etc. Once an explosion starts in an enclosure equipped with an indoor venting system, the pressure build-up will not exceed the design strength, upon which the vent area calculation was based. The explosion heat is dissipated in the venting system so no dangerous flames are released. Rembe themselves have had such a system, the Q-Rohr (Fig. 2), approved in 2014 for metal dust applications. The benefits of the Q-Rohr in containing aluminium dust explosions can be judged Fig 5 Dust collector equipped with Q-Rohr indoor venting system [2] by comparing Fig. 3 and Fig. 4. Explosions with a high content of aluminium dust create very hot and commonly used for this purpose and temperatures of 1650-2200°C, long fireballs, but it can be seen that chemical isolation is also an option. whereas metal powders can easily even with an outdoor dust collector, These mitigation techniques exceed 2750°C. the Q-Rohr could be used to limit are now available for metal dust With metal powder dusts, dust safely the effects of an explosion. processes, but with additional collectors are prone to explosions considerations that need to be by their nature due to the dust that taken into account. Metal dusts are may be stored in them and the high Author different because, even though many potential for ignition sources. NFPA metal powders do not have a high 484 covers the use of wet-type and Dr David Whittaker is a consultant to the Powder Metallurgy and KSt value compared with organic dry-type dust collectors and states materials (except for Al and Mg that that they “shall be located outside associated industries. can exceed 500 bar.m/sec), the risk buildings”. Nevertheless, in practice, Contact +44 1902 338498 Email [email protected] “Explosion venting and isolation are very feasible options in many References [1] Fire and explosion mitigation metal dust applications” strategies for metal powders, A Ibarreta, T Myers, Exponent, USA, of fire and explosions is increased many dry dust collectors are installed as presented at POWDERMET2015, because, in processes generating indoors and this is permitted if a MPIF, USA metal powders, the probability process hazard analysis ensures that [2] Fire and explosion behaviour of of self-ignition is increased. In the risk to personnel and operations metal dusts - protective measures addition, metals and metal powders is properly minimised for new and and peculiarities of their applicability, have much higher energy contents existing systems. There are other G Mayer, E Finley, H Sztarkman, than organic materials. This leads mandatory conditions for indoor Rembe Inc., USA, as presented at to very long burning times, an usage: the minimum ignition energy POWDERMET2015, MPIF, USA issue compounded by the fact that must be greater than 100 MJ, the normal extinguishing agents, such maximum explosion pressure must

as water or sodium bicarbonate, be below 8 bar and the KSt value must cannot be used. After an explosion, be less than 150 bar.m/sec. organic materials can reach burning Explosion venting and isolation

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