Powder Metallurgy Review Winter 2018 Vol 7 No 4

11/06/2019 10:47:45 www.pm-review.com

REVIEW POWDER POWDER

POWDER METALLURGY IN INDIA METALLURGY POWDER PM FOR APPLICATIONS AUTOMOTIVE PLASMA SINTERING SPARK METALLURGY

SUMMER 2019 SUMMER VOL. 8 NO. 2 2 NO. 8 VOL. Ltd Communications Published by Inovar

POWDER METALLURGY REVIEW Vol 8 No 2 SUMMER 2019 © Höganäs AB (publ.), June 2019. 2654HOG 2654HOG 2019. June (publ.), AB Höganäs © www.hoganas.com Höganäs is the pioneer and world leader in metal powders. Our products Our products powders. metal in leader world and pioneer the is Höganäs customers our efficiency inspire and resource servicesand can improve less. with more do to Please come and visit us at: Aachener Kolloquium Euro PM2019 Exhibition) Industry Automotive (Korea Show KOAA Drivetrains Symposium Automotive CTI Inspire industry to to industry Inspire with more lessmake PMR Summer 2019 COVER.indd 1 Are you waiting days or longer to get quotes for thermocouples or thermocouple wire? Does your current supplier think that a normal lead time is 3-4 weeks to ship?

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Are you looking for a QUALITY THERMOCOUPLE MANUFACTURER with real customer service? Contact GEOCORP, INC. today! Publisher & editorial offices Inovar Communications Ltd 11 Park Plaza Battlefield Enterprise Park POWDER Shrewsbury SY1 3AF United Kingdom METALLURGY Editor & Publishing Director Paul Whittaker Tel: +44 (0)1743 211992 REVIEW Email: [email protected]

Managing Director Nick Williams Tel: +44 (0)1743 211993 [email protected]

Assistant Editors Emily-Jo Hopson [email protected] Kim Hayes India’s growing Powder [email protected]

Consulting Editor Metallurgy market Dr David Whittaker Consultant, Wolverhampton, UK Having attended the APMA Conference this year in Pune, Advertising Sales Director India, it was evident that the Indian Powder Metallurgy Jon Craxford market is thriving, reporting continued growth that is Tel: +44 (0) 207 1939 749 mirroring the state of the country’s expanding automotive [email protected] sector. Production Hugo Ribeiro, Production Manager The country’s PM structural part makers are not just Tel: +44 (0)1743 211994 [email protected] subsidiaries of leading global PM companies, but also include many locally established enterprises. As Accuracy of contents the market grows, investment in these companies is Whilst every effort has been made to ensure the accuracy of the information in this publication, continuing, with many reporting facility expansions. the publisher accepts no responsibility for errors or omissions or for any consequences Not content with meeting the needs of the growing local arising there from. Inovar Communications Ltd cannot be held responsible for views or claims market, a number of the larger PM part manufacturers expressed by contributors or advertisers, which are also seeking to attract new overseas customers. are not necessarily those of the publisher. Reporting from within the industry, Kadambari Gopinath,

Reproduction, storage and usage offers a unique insight into the region, considers the state Single photocopies of articles may be made of its automotive market and identifies the key players in for personal use in accordance with national the country’s PM structural parts industry. copyright laws. Permission of the publisher and payment of fees may be required for all other photocopying. There are, of course, many applications in the All rights reserved. Except as outlined above, automotive sector for the use of Powder Metallurgy. The no part of this publication may be reproduced, process offers numerous advantages over alternative stored in a retrieval system, or transmitted in any manufacturing routes, from cost savings to novel designs form or by any means, electronic, photocopying or otherwise, without prior permission of the and unique material properties. Much of this innovation publisher and copyright owner. has been recognised through industry awards over the

Submitting news and articles years and in this issue, we present award winning PM We welcome contributions from both industry structural parts from the automotive sector. and academia and are always interested to hear about company news, innovative applications for PM, research and more. Paul Whittaker Please contact Paul Whittaker, Editor Email: [email protected] Editor, Powder Metallurgy Review

Subscriptions Powder Metallurgy Review is published on a quarterly basis. It is available as a free electronic publication or as a paid print subscription. The annual subscription charge is £95.00 including shipping.

Design and production Cover image Inovar Communications Ltd. ABS sensor rings are just ISSN 2050-9693 (Print edition) ISSN 2050-9707 (Online edition) one of the many automotive © 2019 Inovar Communications Ltd. components suited to

This magazine is also available for free Powder Metallurgy (Courtesy download from www.pm-review.com Sintercom India)

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41 55 61 72 89 in this issue

57 The Powder Metallurgy market in India: 89 Spark Plasma Sintering: Method, systems, Potential for continued growth as auto applications and industrialisation industry advances For around thirty years, Spark Plasma Sintering India produced a total of 31 million vehicles last (SPS) has been of great interest to the Powder year, including passenger and commercial vehi- Metallurgy industry and academia alike, for cles as well as three and two-wheelers, making both product manufacturing and advanced it the fourth largest automotive manufacturer material research and development. Today, a in the world. The domestic market for sintered number of components made using SPS are components is growing at a CAGR of 22%, with already in production, with the process moving many businesses reporting further investment from the R&D stage to practical industrial use. and new product lines. In this review, Kadambari In this article, Dr Masao Tokita, of NJS Co., Gopinath, reports on the current state of India’s Ltd., introduces the latest in SPS technology, automotive market and provides an insight into discusses the development of the production the country’s growing PM industry. systems and highlights a number of industrial applications. 71 Award winning automotive applications showcase potential of PM Powder Metallurgy can be used to produce a wide range of automotive components. The technology offers numerous advantages over other metal working processes, from reduced manufacturing costs to improved properties and unique material characteristics. Over regular features recent years, many of these parts have been the recipient of industry awards, and in this article, 6 Industry news Dr David Whittaker highlights a number of the 105 Events guide winning parts to showcase the potential for PM in the automotive sector. 106 Advertisers’ index

Toindustry submit news for inclusion in Powder Metallurgy Review contact Paulnews Whittaker, [email protected]

Sumitomo Electric Industries acquires PM companies from Sinterwerke Group

Sumitomo Electric Industries Ltd. Speaking on the announcement, (SEI), Osaka, Japan, has acquired Sinterwerke Group stated that the both European Powder Metallurgy acquisition marks an important businesses of Sinterwerke Group; move towards increasing its global Sinterwerke Herne GmbH, Germany, presence and implementing the and Sinterwerke Grenchen AG, Swit- latest production process technolo- zerland. gies. SEI’s Powder Metal Products Together, the two Sinterwerke division operates globally, with Sinterwerke produces a range of businesses produce a wide range Sumitomo Electric Sintered Alloy PM components for the automotive of Powder Metallurgy components, Ltd. headquartered in Okayama, and power tool industries (Courtesy primarily for the automotive and Japan. The division provides a variety Sinterwerke) power tool markets, with customers of products, primarily for Japanese said to include Tier1 automo- manufacturers of cars, automotive tive suppliers and OEMs. The two components and air conditioners. facturers, while increasing the companies posted combined sales SEI stated that its latest acquisi- presence of its Powder Metallurgy of approximately €71 million in 2018 tions will help to expand its sales products business in Europe. and jointly list 400 employees at channels to include European www.sinterwerke.com facilities in Germany and Switzerland. automakers and component manu- www.global-sei.com

Melrose reports no immediate plans to a clear expectation that they be good stewards of their businesses for the offload GKN Powder Metallurgy benefit of all stakeholders.” In the Annual Report for the Melrose Industries PLC, UK, has Nortek Air & Security; and Other year ended December 31, 2018, reported that, despite earlier plans Industrial. the company announced statutory for a quick sale of the GKN Powder “For the GKN businesses, revenue for the Melrose group of Metallurgy division, the company has decentralisation was the first step in £8,605 million (2017: £2,092 million) no immediate plans to sell the busi- bringing about the change in culture and, despite declaring a statutory ness. In its recently published 2018 we believe is vital to securing long- operating loss of £392 million (2017: Annual Report, Melrose stated that, term improvement,” stated Simon £7 million), primarily as a result of “whilst we will continue to review the Peckham, Melrose’s Chief Execu- the required accounting for the GKN position in the months to come, we tive. “For GKN Aerospace and GKN acquisition, its adjusted operating expect GKN Powder Metallurgy to Powder Metallurgy, we worked with profit was £847 million (2017: £279 remain in the group for the present.” incumbent management teams to million). Upon taking control of GKN, agree their management plans.” “The former GKN businesses Melrose stated that it set about “Having agreed their approach, are proving their potential to offer removing the duplicate central the GKN businesses have been the outstanding opportunities we functions and decentralising the given the freedom and responsibility expected and much has already GKN businesses, simultaneously to start to deliver on their commit- been achieved in the short period of reorganising the Melrose Group into ments. Part of this has been a ownership,” added Justin Dowley, five divisions: GKN Aerospace; GKN refocus on profitable sales rather Melrose’s Non-executive Chairman. Automotive; GKN Powder Metallurgy; than solely on growth. There is also www.melroseplc.net

Rio Tinto Metal Powders (RTMP) is a registered ISO9001, Through our research and development activities ISO14001 & IATF16949 company and is the only major and close collaboration with our customers, industry powder producer in the world to manufacture iron powder associations and research institutes, Rio Tinto from low residual ore. As a result, RTMP offers exceptional Metal Powders is well positioned to capture the evolving consistency in its full range of iron and steel powders. future needs of the powder metallurgy industry.

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GKN Powder Metallurgy opens North American PM Headquarters

GKN Powder Metallurgy has opened its new North American Powder GKN Powder Metallurgy opens North American PM Headquarters and AM Metallurgy Headquarters and Addi- Customer Center (Courtesy GKN Powder Metallurgy) tive Manufacturing Customer Center in Auburn Hills, Michigan, USA. The new facility will house over eighty manufacturability and materials advanced technology we create for employees from the three divisions in the early stages of the develop- our customers. This building rein- of GKN Powder Metallurgy; GKN ment process. It is expected that the forces our commitment to the North Hoeganaes, GKN Sinter Metals and full 38,260 ft2 combined facility will American market and continued GKN Additive. expand the company’s global Addi- global growth.” The building includes a 3,200 ft2 tive Manufacturing network and the “GKN Powder Metallurgy is at Additive Manufacturing Customer scope of its in-house Powder Metal- an exhilarating point in its journey Center, equipped with two EOS M290 lurgy capabilities. of growth and innovation,” Southby metal Laser Powder Bed Fusion Reid Southby, President of GKN continued. “We now have the oppor- (L-PBF) systems. EOS’s systems are Sinter Metals Large Segment, tunity to provide our customers and capable of manufacturing functional stated, “We are excited to start a strategic partners with local and metal prototypes within a two-week new journey in Auburn Hills with exceptional support on all fronts of lead time and allow customers to test a space that is dedicated to our our business.” factors such as usability, ergonomics, team, our community and the www.gknpm.com

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Miba reports continued growth as revenue exceeds €985 million

Miba AG, Laakirchen, Austria, has The group has reportedly invested reported strong growth in its fiscal €87 million in property, plant and year 2018–2019 (February 1, 2018 equipment and intangible assets and to January 31, 2019). Revenue has €41 million in research and develop- increased 11% year on year to €985 ment. “By investing in our plants, million, which positions the group in research and development and closer to its revenue target of €1 in our employees’ expertise, we are F Peter Mitterbauer, CEO (left) and billion set out in the Miba 2020 – creating the basis for our further Markus Hofer, CFO (right) (Courtesy Dynamic Evolution strategy. growth,” continued Mitterbauer. Miba AG) According to the group, its “Thanks to our financial stability and annual revenue has more than our independence as a family-owned doubled since 2010, rising by over company, we are best placed to invest tive sector will be integrated. The half a billion euros. “The past fiscal over the long-term and with a steady company has reportedly created year saw challenging market condi- hand. This enables us to safeguard over 1,100 additional jobs in Austria tions in the automotive segment existing jobs and create new ones.” since 2010. “In Vorchdorf, we are and showed once again that, with Miba states that it is in the process planning to build additional capacity its very broad product portfolio and of building three new plants in China for the e-mobility business,” added its focus on a number of regional and India, in order to accommodate Mitterbauer. “By doing so, we are markets, Miba is very well prepared growth in Asia. It is also expected to maintaining our strategy of investing to manage volatility in individual build an eMobility Cluster in Austria, heavily in Austria as well as growing market segments,” stated F Peter where the Group’s expertise from globally.” Mitterbauer, CEO of Miba AG. electrification and the automo- www.miba.com

175mmx120mm PMReviewSPRING2018.pdf 1 3/20/18 10:00 AM

Oerlikon finalises sale of Bodycote invests in new Drive Systems Segment to North American heat Dana Incorporated treatment facility

Oerlikon has announced the sale of its Drive Systems Bodycote plc, a global provider of heat treatment and Segment to Dana Incorporated. The agreement to specialist thermal processing services headquartered in divest was signed and announced in July 2018 and, after Macclesfield, Cheshire, UK, is expanding its capabilities receiving the required regulatory approvals and satis- in North America with the launch of a new heat treating fying all closing conditions, the sale is now successfully facility in Elgin, Illinois, USA. According to the company, completed. the new facility will offer advanced heat treating tech- “The closing of the transaction marks the next nologies such as low-pressure carburising and carboni- milestone in the execution of our strategy,” stated Dr triding, vacuum nitriding and ferritic nitrocarburising, Roland Fischer, CEO of Oerlikon Group. “Following the Bodycote’s Corr-I-Dur® process, and traditional carbur- sale, we will now concentrate our efforts and resources ising of large parts. in sustaining the growth and performance of our surface Operating from more than 180 accredited facilities solutions and man-made fibres businesses.” in twenty-three countries, Bodycote provides classical The transaction is said to free up resources for heat treatment and specialist technologies including Hot Oerlikon to fund innovation, invest in organic and inor- Isostatic Pressing (HIP) to a wide range of industries, ganic growth and to further implement digital and opera- including aerospace, defence, automotive, power genera- tional excellence initiatives to drive future growth. The tion, oil & gas, construction, medical and transportation. transaction has an enterprise value of CHF 600 million The new facility is expected to be operational by late 2019 (approx €530 million). and will support the automotive, agricultural, mining, www.oerlikon.com construction and other manufacturing supply chains in www.dana.com the USA’s Upper Midwest. Dan McCurdy, Bodycote’s President of Automotive & General Industrial, North America & Asia division, stated, “This investment demonstrates Bodycote’s commitment to serving the Midwest with the services our customers ask for and require.” www.bodycote.com Since 1999 Arcast produces fine The Leader Of High Quality titanium superalloy powder

Micro-nano Ultrafine Metal Powder Arcast Inc., Oxford, Maine, USA, reports that it has successfully produced a titanium superalloy powder with Iron powder an as-atomised D50 of 20 µm, with narrow size distribu- Copper powder tion and with little-to-no oxygen pick-up. The alloy was High iron-base produced using Arcast’s proprietary atomising process. Pre-alloyed powder Sustitution of Arcast’s process consumes relatively little gas and has Co powder, Ni powder zero risk of ceramic/oxide contamination, the company states, making it possible to process metal alloys which other methods cannot. Powders produced by this method can be used in Additive Manufacturing, Metal Injec- tion Moulding and other Powder Metallurgy processes. The production of powder by this process also does not require specialist feedstock. Arcast stated that the new alloy is now being produced in significant quantities. With its growing capacity to produce as-atomised, advanced titanium alloys (along Looking for distributors with other challenging metal alloys) from a range of low- 2325 Pv Drive West# 201, Palos Verdes Estates, CA 90274 cost feedstock, Arcast states that it can offer a complete [email protected] (424)327-2642 solution for Additive Manufacturing, Metal Injection www.sagwellusa.com Moulding and other Powder Metallurgy markets. www.arcastinc.com

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MPP Ltd PM Solutions by Design Sandvik completes acquisition of Kunshan Ousike Precision Tools

Sandvik has completed its acquisi- Solutions, stated, “The acquisition tion of Kunshan Ousike Precision is aligned with Sandvik Machining Tools Co., Ltd (OSK), a supplier of Solutions’ focus on growing the round solid carbide round toolsMPP based Ltd in manufacturestools business. We are already today Kunshan, Jiangsu, China.both OSK large will andwell smallpositioned lots, in China but OSK will MPP Ltd - your Partner in be part of the Seco Tools division of bring us even closer to customers.” delivering powders in metal powder processing Sandvik Machining Solutions. OSK was established in 2006 and The acquisition is expectedquantities to asin low2017 reportedas 5kg revenues of SEK Ÿ Powders tailored to your strengthen Seco Tools’through position and to multi-tonnage120 million and employed a staff of requirements product offering in theorders. fast-growing ninety. Both parties have agreed not Chinese electronics industry. At the to disclose the purchase price. Ÿ Clean, spherical powders time of the acquisition agreement www.home.sandvik in November 2018, Klas Forsström, www.secotools.com President of Sandvik Machining www.osktool.com Ÿ Flexible - R&D to production

Ÿ Optimised for AM Horizon Technology discusses durability when selecting metal powders

Horizon Technology, St. Marys, as corrosion resistance, hardness, Pennsylvania, USA, recently made tensile strength, impact toughness available a number of online guides and fatigue strength. designed to provide an introduction to The guide also covers ‘Materials various Powder Metallurgy processes and Their Qualities’, breaking down and applications. The company has the properties and advantages/ now added a new guide, ‘Choosing disadvantages of stainless steel, Powder Metallurgy Materials Part 1: copper, nickel, aluminium and Durability’. titanium. This is the first in a series on The guide is available to read for selecting PM materials and lists free on the company’s website. what factors should be considered www.horizontechnology.biz before constructing a PM part, such Please contact us to discuss your requirements for customised powder development for both MPIF releases updated Standard 35 for R&D and large scale production www.metalpowderprocess.co.uk PM Self-Lubricating Bearings Application of MPP Powders The Metal Powder Industries Federa- provides explanatory information for tion (MPIF) has released the 2019 the materials listed. The standard, Ÿ Automotive edition of its MPIF Standard 35–SLB, developed by the Powder Metal- Ÿ Aerospace Materials Standards for PM Self- lurgy commercial parts manufac- Ÿ Energy Storage Lubricating Bearings. This standard turing industry, has reportedly been Ÿ Energy Generation provides the design and materials revised to make it cleaner and more Ÿ Medical engineer with the latest engineering concise. property data and information MPIF Standard 35-SLB does not available to specify materials for apply to materials for PM Structural Metal Powder & Process Limited Chaucer Business Park - Dittons Road structural parts made using the PM Parts, powder forged or metal injec- Polegate - East Sussex - BN26 6JF - UK process. tion moulded (MIM) products, which Tel: +44 (0)1323 404 844 Each section of the standard is are covered in separate editions of [email protected] distinguished by easy-to-read data MPIF Standard 35. www.metalpowderprocess.co.uk tables (Inch-Pound and SI units) and www.mpif.org

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of high-performance components Epson Atmix installs new production line found in products ranging from for amorphous alloy powder at its Kita- automobiles to smartphones to medical equipment and more. Epson Inter Plant Atmix states that the demand from these types of industries has been Epson Atmix Corporation, Aomori, 800 million yen (USD $7.4 million) to growing, and this trend is expected Japan, has launched a new produc- implement the new line and plans to to continue for the foreseeable tion line for amorphous alloy powder increase its amorphous alloy powder future. at its Kita-Inter Plant, Hachinohe, production capacity to approximately Epson Atmix believes it was Aomori Prefecture, Japan. A division 6,000 tons per year by 2023. the first company in the world of Seiko Epson Corporation, Epson The company’s superfine alloy to successfully volume-produce Atmix has invested approximately powders are used in the manufacture amorphous alloy powder using its SWAP (Spinning Water Atomisation Process) production method in 2004. Amorphous alloy powders are reported to have high magnetic flux densities and low energy loss in addition to excellent high-frequency characteristics. These characteristics make amorphous alloy powders extremely attractive as performance-enhancing, highly functional material powders that enable small, low-power voltage control components and that support high frequencies and large currents. The new production for amorphous alloy powder has begun operation at its www.atmix.co.jp Kita-Inter Plant (Courtesy Epson Atmix)

GEA launches its R55 industrial rotary press for powder compaction

GEA Group AG, Düsseldorf, Germany, The system’s top and bottom air debuted its new R55 industrial compensators are designed to enable rotary press during Powtech 2019 in truly symmetric constant-density Nuremberg, Germany, April 9–11, compression, while a hold down/ 2019. The fully-automated R55 is hold up system provides a method capable of compacting a range of by which to control vertical stresses materials for the manufacture of during ejection. This enables the R55 products including hard metals, to emulate the functionality of both GEA’s new R55 industrial rotary press nuclear fuel pellets, batteries, hydraulic and electric single-stroke (Courtesy GEA Group AG) confectionary and pharmaceuticals. presses while providing a higher The new press is said to incor- output. between two large compression porate the latest technologies to To reduce the risk of damage to rollers. help ensure flexibility, precision, products, the press also incorporates During press operation, GEA’s operator safety and minimal main- a takeoff wheel, replacing the In-line Density Control (IDC) tenance requirements. It is available conventional ejection bar, for the measures the diameter and height with a number of optional features, removal of fragile parts horizontally of all tablets and weighs up to 100 designed to improve and expe- from the press directly onto a products per minute. Where varia- dite the production process while conveyor belt. In addition, continuous tions are identified, through instant providing higher levels of control, and powder flow is said to ensure a density calculations, the press will is reportedly capable of outputting narrow weight distribution. Gentle adjust its compression force and more than 30,000 products per hour pre-compression also facilitates fill depth to keep the average part at a maximum compression force of powder deaeration and prepares the density and height constant. 130 kN. formulation for its final compression www.gea.com

Metals Construction begins on Ceratizit plant extension

Powder Metal Lubricant Construction is now underway on an extension to Ceratizit Austria GmbH’s manufacturing plant in Reutte, Austria. According to Ceratizit’s parent organisation Acrawax® C Lubricant Plansee SE, the new build will be ready for occupation by Spring 2022, and will house a staff of up to 300. Setting the standard in the metal powder industry, Acrawax® C The extension to the plant reportedly involves an Lubricant is a clean-burning, metal-free lubricant that does investment in the double-digit million euro range, and the not generate metallic or corrosive byproducts. Acrawax® C new facility is set to comprise a multi-storey building with a length of 200 m and width of 80 m. To combine the old Lubricant is combustible, leaving no residue on sintered parts. plant with the new building, Ceratizit will pave a previously privately-used gravel road to route internal plant traffic away from public roads. At present, three companies of the Plansee Group operate out of the same industrial park in Reutte. While Plansee SE manufactures semi-finished products and components made of tungsten and molybdenum metals, Ceratizit Austria specialises in the production of carbide tools for machining processes. The new building will house the Grinding Shop and Tool & Die, enabling Ceratizit Austria to meet the strong global demand for hard metal tools. www.ceratizit.com | www.plansee.com

Arcast metal powders certified for commercial, aerospace & defence

Arcast Inc. and Arcast Materials Division, Oxford, Maine, USA, have achieved certification to ISO 9001:2015 and AS9100D for the manufacture and sale of metal powder and castings for commercial, aerospace and defence applications. Arcast stated that it built its new materials division around these quality management systems to ensure its ability to meet the industry’s most demanding requirements. The new certification means that Arcast’s metal Acrawax® C Lubricant Offers: powders, as well as its casting products, can now be sold to a wide range of markets, including aerospace, – Precise particle size control with the confidence that it can meet the quality stand- – Free flowing powder mixes ards required by its customers. With its growing capacity to produce as atomised titanium alloys (along with other – Low die wear and easy part removal from the die challenging metal alloys) with a D50 of 30-40 µm from – Reduced part distortion a range of low-cost feedstock, Arcast states that it can – Variety of custom particle sizes offer a complete solution for Additive Manufacturing, Metal Injection Moulding and other Powder Metallurgy markets. “Our ultra-clean and high-performing processing method offers the highest possible quality powder and www.lonza.com is now backed up by a quality standard that matches it,” [email protected] commented Sasha Long, Arcast Vice President. www.arcastinc.com

By region, 38% of Sandvik’s Sandvik Group reports its best ever revenues came from Europe, 21% earnings in 2018 from North America, 20% from Asia, and a further 9% from Africa/ Sandvik AB, Stockholm, Sweden, (2017: SEK 18,073). The adjusted Middle East, 7% from Australia and has published its Annual Report operating margin for 2018 was 5% from South America. Sandvik for 2018. The company stated that reported to be 18.6% (2017: Machining Solutions represented 2018 had been a record year, in 16.1%), with a free operating cash 53% of the group’s total adjusted which it achieved the best earn- flow of SEK 15,281 million (2017: operating profit, with Sandvik ings in its history and a record- SEK 15,095 million). Mining and Rock Technology repre- high operating margin, with sales According to the report, senting 39% and Sandvik Materials exceeding SEK 100 billion for the Sandvik saw strong development Technology 7%. first time ever. The group stated in all customer segments and In 2018, Sandvik Group that this was partly influenced by in all geographical regions in concluded the divestment of a positive economic climate, with 2018, with order intake showing Sandvik Hyperion and its wire favourable demand in all of its overall growth of 9% from 2017. operations (welding wire and segments and on all continents, as A breakdown of revenues by stainless wire) and made a new well as recent work to decentralise customer segment showed that investment in a manufacturing and streamline the company’s 34% of the groups revenues plant for titanium and nickel activities. came from the mining segment, powder. It also completed several The group reported an order 23% from engineering, 12% from strategic acquisitions, including intake of SEK 102,440 million automotive, 11% from energy, 9% the metrology software company (2017: 95,444) with revenues total- from construction, and 6% from Metrologic Group and industrial ling SEK 100,072 million (2017: aerospace, with the remaining 5% heating company Custom Electric 90,827). An operating profit of of revenues coming from other, Manufacturing. SEK 18,689 million was recorded unspecified segments. www.home.sandvik

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AMETEK SMP Eighty Four and Reading Alloys are global leaders in the production of Water and Gas Atomized stainless steel and high-alloy powders for P/M, Filtration, MIM, and Thermal Spray. www.readingalloys.com email: [email protected] • AUSTENITIC STAINlESS STEEl • FErrITIC STAINlESS STEEl • HIgH PUrITy HydrIdE-dEHydrIdE TITANIUm PowdErS www.powderclad.com • SPECIAlTy AlloyS email: [email protected]

efficiency,” added Lång. “To get “As we are convinced that metal Höganäs publishes closer to our vision, the necessary powder can improve society, it is its sustainability co-operation with industry partners, natural for us to integrate sustain- academia and society’s various ability in our business. We strive report for 2018 actors will continue in the years to not only to reduce our own nega- come.” tive impact, but also to contribute Sweden’s Höganäs AB has released One such joint activity is a pilot- positively to society through more its second annual sustainability scale plant for renewable energy sustainable solutions. Systematic report, highlighting the company’s gas, which is currently under start- assessment of our products’ life- activities and sustainability perfor- up for testing at the company’s site cycles will help us meet customer mance in 2018. As the leading in Höganäs, Sweden. If successful, it expectations and promote the prod- producer of iron powders, Höganäs will be integrated permanently into ucts’ sustainability advantages with a employs around 2,500 staff across operations and replace about 50 GW knowledge-based approach,” added eighteen production units in eleven hours of non-renewable energy per Emilson. countries. Its product portfolio year from 2020. www.hoganas.com contains more than 3,500 products and the company serves around 3,000 customers globally. In the report, Fredrik Emilson, We create a new sintering world Höganäs President and CEO, stated, “2018 was characterised by high U-FAST: UPGRADED FIELD ASSISTED SINTERING TECHNOLOGY demand for our metal powders, organisational changes and integration of new acquisitions. Even though high demand is positive, it also brings challenges. We have done our utmost to balance our customers’ needs and deliver according to plan. Our co-workers have accomplished great results despite the high workload.” Höganäs stated that it is on track to decrease energy use by 10% by 2020 compared to energy usage in 2010. The 2018 result was said to show an 8.7% decrease. One of the company’s goals is to become a climate neutral operation, minimising its climate footprint through both established and newly devel- Flexible adaptation to the user requirements Parameters oped methods. “We also need to Max. pulse current [kA] 10 •Consolidation of a wide range of innovative materials. invest in research and innovation to Max. output voltage [V] 14 •Nano-grain materials due to very short pulse < 1ms. make improvements beyond what is •Suitable for academia and small batch production. Pulse duration [ms] 0.8 - 500 possible today,” added Nicklas Lång, •Modular device in accordance with Industry 4.0. Temperature measurements [oC] 0 - 2500 • Software adjustable to the specific needs of the Vacuum [mbar] 10-2 - 10-6 Senior Vice President Sustainability, technological process. Maximum pressing force [kN] 350 Höganäs Group. •Multpoint temp. measurment. Max. sintered components [mm] Ø 85 A long term Climate Roadmap, • Manual, semi or automatic process control. Max. diameter of graphite die [mm] 200 which aims to decouple earnings Additional pause [ms] 0 - 999 from climate impact emissions, Number of pulses 1 - 500 is reported to be underway. “The Climate Roadmap will guide the strategy and business planning, as well as form the basis for action plans in the years to come. The areas Take an adventage from our on-site sintering service and material covered in this work are, among development labolatory. others the upstream scope 3 CO2 GeniCore Sp. z o.o. emissions, efficient sourcing of raw Tel: +48 22 857 04 77 e-mail: [email protected] materials and transports, supply of fuels and energy and internal energy www.genicore.pl

William Rowland in £10m expansion and relocation

William Rowland, recognised as one of the oldest metal trading businesses in the UK, has announced it is relocating to a new £10 million state-of-the-art manufacturing facility in Barnsley, South Yorkshire. The company has operated from its existing site in nearby Sheffield since 1870, and the move to a new 6.5-acre site is expected to allow it continue on its current growth trajectory. It was stated that several new product lines have been added in the last two years which support its transformation into a manufacturing business, with the addition of several new processes across its refined metals, metal powders and speciality alloys segments. “It was critical we removed the obstacles to our continued growth and put ourselves in a position to help our customers and suppliers grow their businesses,” stated Richard Lowe, MD for William Rowland. “In selecting the site, we had to consider our strongest asset (employees) first, as without them we cannot provide the outstanding levels of expertise and service our customers are accustomed to. Additionally, we wish to become an employer of choice and, whilst we are The powder makes renowned for service and stability, a modern place of work will help with that.’’ the difference William Rowland is owned by Amalgamated Metals Corp (AMC), who operate a variety of non-ferrous metals Meeting the highest standards businesses globally and also offer a range of risk manage- for drying and powder quality ment services to the metals sector. “Our parent company has a stable and balanced portfolio, and long term perspective which enables significant investments of this GEA spray drying plants unite innovation type, even when the economic climate is uncertain,” Lowe and experience to state-of-the art process continued. technology for the production of hard “The site will be fully operational in the first half of metals and advanced ceramics. We have 2020, with the No. 1 objective of no disruption to our pioneered this technology, and our expertise valued customers. I am really confident we can achieve helps you to meet the highest standards a move with little disruption, we are in control of the of powder quality, powder size distribution, disposal of the current site and have duplicate facilities in residual moisture content, bulk density the West Midlands from where we can build buffer inven- and particle morphology. All GEA plants tory.” are designed to comply with the strictest www.william-rowland.com requirements regarding eﬃ ciency, health and safety and environmental compliance. Customer-oriented service concepts guarantee a seamless support for instant productivity and performance.

For contact details: gea.com/contact

William Rowland is relocating to a new £10 million state- of-the-art manufacturing facility

Reading Alloys Nabertherm appoints Timm Grotheer appoints Michael its new Managing Director

Wilkes as its new Nabertherm GmbH, Bremen, Under Wentrot, Nabertherm Product Manager Germany, has announced the reported that it has seen global appointment of Timm Grotheer success, employing more than 500 staff for Powders as its new Managing Director. and achieving a turnover of more than Grotheer, who previously served as €60 million ($68 million). A key element Managing Director of shipbuilding has been the consistent internation- Reading Alloys, a division of Ametek group Lürssen, succeeds Frie- alisation of the business, which now Specialty Metal Products (SMP), drich-Wilhelm Wentrot, who has has an export share of 70%, selling its headquartered in Robesonia, Penn- served as Managing Director of the furnaces and plants around the world. sylvania, USA, has announced the company for eighteen years. www.nabertherm.com appointment of Michael Wilkes as its new Product Manager for Powders. Wilkes will be overseeing the ongoing growth of Reading Alloys’ range of powder-based products, including high-purity titanium and titanium alloy powders produced via a hydride- Fine Grinding Mills dehydride (HDH) process and used for coatings in orthopaedic medical are Just the Beginning devices, advanced electronics, traditional Powder Metallurgy and metal Additive Manufacturing. Wilkes previously worked as Director of Global Customer Service at Carpenter Technologies in Reading, Pennsylvania, USA. In that role, he was responsible for leading global customer service quality, inside sales and customer service teams at seven global locations while also supporting multiple brands and For over 70 years, Union Process has been building the finest size reduction products. He holds a BSc in Manage- equipment in the industry for some of the largest companies ment and Marketing from Pennsyl- in the world as well as start-ups who need to test before they grow. vania State University and has also Whether it’s dry grinding metal powders for chemical processes, completed the Executive Education magnetic composites, polymer friction or any application, Union Process General Management Program at has the equipment and more importantly, the know-how to help you Harvard Business School. every step of the way. www.readingalloys.com

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Phone: 330.929.3333 • www.unionprocess.com ISO 9001:2015 w/DESIGN Reading Alloys has appointed Michael © 2019 Union Process, Inc. All rights reserved. Wilkes as its new Product Manager for Powders EXPANDING THE POSSIBILITIES FOR SIZE REDUCTION™

Höganäs rebrands GKN Sinter Metals begins construction H.C. Starck division of new facility in Mexico

Höganäs AB has announced that as GKN Sinter Metals has officially stated Mauricio Usabiaga Diaz of June 1, 2019, it has rebranded begun construction of its new Powder Barriga, Guanajuato Secretary of its H.C. Starck Surface Technology Metallurgy parts making facility in Economy Development. & Ceramic Powders (STC) division Guanajuato, Mexico. The plant will During a ground-breaking under the main Höganäs brand. include almost 6,000 m2 of roofed ceremony with business partners Höganäs acquired the STC division area and employ up to 250 people and representatives from the local from H.C. Starck, along with two when fully operational. government in attendance, Peter production units, in March 2018. It was stated that the site is Oberparleiter, GKN Powder Metal- “Together we are a leading perfectly positioned to support lurgy CEO, reconfirmed the compa- provider for all surface and joining local Mexican customers, adding to ny’s commitment to its operations in technologies, including thermal GKN Sinter Metals’ leading posi- Mexico, stating: spraying, hard facing, brazing and tion in automotive and industrial “It is part of our strategy to have welding. As one Höganäs organi- markets, as well as its strategic operations in our key markets and sation, we utilise our joint forces focus to expand products in elec- in close proximity to our customers. to invent better solutions for our trical systems, solutions in X-by- Reflecting the strong development of customers’ current needs and Wire systems, e-pump technology, the Mexican automotive and indus- future challenges,” stated Hans connected home technologies, etc. trial sector over the recent years this Keller, President Product Area “We are proud to welcome GKN investment was a natural step. We Surface & Joining Technologies at Sinter Metals in the state of Guana- are excited to see local production Höganäs. juato, a company with high tech- beginning in August with the objec- The company stated that it aims nology products and a company with tive to have full operations and local to make surface coating a new and a large global footprint. Our state supply from Guanajuato in 2019.” strong business division, alongside welcomes GKN with open arms,” www.gknpm.com its metal powder for press and sinter components. “Now that we are truly one company, Höganäs is one of the largest players in the premium segment of the surface coating market, servicing a broad range of industries, but focusing on automotive, oil and gas, mining and construction, energy and aviation,” added Keller. www.hoganas.com Breaking ground for construction of GKN’s facility (Courtesy GKN Sinter Metals)

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since 1917 G DRY BAG PRESSES PISTON EXTRUDER G LOOMIS PRODUCTS Kahlefeld GmbH CONTINUOUS PISTON EXTRUDER G PISTON EXTRUDER 16 T - 500 T LOOMIS PRODUCTS COMPANYLABORATORY PRESSES CIP-COLD-ISOSTATIC-PRESSES CONSULTATION AND COMPLETE PLANT DESIGN PISTON EXTRUDER G WET BAG PRESSES uy the TOOLING Buy the Original, Buy Quality!b orig G DRY BAG PRESSES GinCONTINUal · buOUSy qu PISTONality EXTRUDER Stockwiesen 3 · 67659 Kaiserslautern/GermanyG PISTON · Tel +49 EXTRUDER (0)6301-79999-70 16 T ·- Fax500 +49 T (0)6301-79999-92 · [email protected] · www.loomis-gmbh.de LABORATORY PRESSES CONSULTATION AND COMPLETE PLANT DESIGNsince 1917 PISTON EXTRUDER G LOOMIS PRODUCTS Kahlefeld GmbH CONTINUOUS PISTON EXTRUDER TOOLING G PISTON EXTRUDER 16 T - 500 T LOOMIS PRODUCTS COMPANY CONSULTATION AND COMPLETE PLANT DESIGN Stockwiesen 3 · 67659 Kaiserslautern/Germany · Tel Stockwiesen+49 (0)6301-79999-70 3 | 67659 Kaiserslautern/Germany · Fax +49 (0)6301-79999-92 | Tel +49 · [email protected] (0)6301-79999-70 ·| www.loomis-gmbh.deFax +49 (0)6301-79999-92uy | [email protected] | www.loomis-gmbh.de TOOLING b orig inal · buy quality

22 Powder Metallurgy Review Summer 2019 Stockwiesen 3 · 67659 Kaiserslautern/Germany© 2019 · Tel Inovar+49 (0)6301-79999-70 Communications ·Ltd Fax +49 (0)6301-79999-92 · [email protected] · www.loomis-gmbh.de DSH_FullPage_International_M1A.pdf 1 4/9/19 4:35 PM

N C H O L E O T G H I E S S D

C S E L R E A B E R Y A 0 WE’RE T I N G 2 WITH YOU

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M Y OF THE WAY. CM MY At DSH Technologies, we take you step CY

CMY by step throughout the entire process,

K whether you have processing related questions, experiments, facility optimization goals or contract work related to any debind and sinter technology, we’re here to help. Our goal is to breed parts makers. We take pride in educating our customers; we want our customers to build the foundation and confidence with the process, so they can take the work, bring it in-house and become successful with their own team and from the support of our team.

We’re in this together.

Japan’s Powder Metallurgy industry remains stable

The Japan Powder Metallurgy Association (JPMA) has reported that the production of Powder Metal- lurgy structural parts and sintered bearings in Japan remained stable in 2018. Figures released by the Japan Ministry of Technology and Industry (METI) showed that structural (machine) PM part production was 88,605 tons in 2018, up from 88,484 in 2017. Sintered bearing production fell slightly, with 6,704 tons produced in Fig. 1 Structural (machine) PM part production in Japan (Courtesy JPMA) 2018, compared to 6,741 tons in the previous year. The reported value of both structural PM parts and sintered bearings increased in 2018. PM structural (machine) parts were valued at Yen 112,671 billion in 2018, up from Yen 110,904 billion in 2017, with the value of sintered bearings increasing to Yen 16,033 billion in 2018 from Yen 15,843 billion in 2017. The statistics published by the JPMA also revealed that 95% of structural PM parts, and 78% of PM bearings, were used in automotive applications. The consumption of PM parts in a typical car produced in Japan was said to be 8.8 kg. www.jpma.gr.jp www.meti.go.jp Fig. 2 Production of PM bearings in Japan (Courtesy JPMA)

growth and improving long-term Sandvik Materials Technology to shareholder value,” stated Johan separate from the Sandvik Group Molin, Chairman of the Sandvik Board of Directors. Sandvik AB, Stockholm, Sweden, is According to the company, the Björn Rosengren, President to initiate an internal separation of its separation is expected to take at and CEO of Sandvik, commented, business division Sandvik Materials least a year, with no guarantee “Sandvik Materials Technology Technology. The decision was made whether a decision to list Sandvik represents the origin of Sandvik by Sandvik’s Board of Directors with Materials Technology at the Nasdaq and great businesses have sprung the reported aim of increasing the Stockholm Exchange will be taken. out of it to shape the current structural independence of Sandvik “The decision to initiate an internal structure. It is my view that a Materials Technology from the separation of Sandvik Materials separation will allow full focus on Sandvik Group. It is expected that Technology is based on the board’s Sandvik Materials Technology’s key this will put a significant focus on the belief that each part will develop strengths and its further improved business’ future development possi- more favourably by itself, increasing performance.” bilities, as well as creating flexibility. opportunities for profitable www.home.sandvik

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SMS group GmbH Ohlerkirchweg 66 41069 Mönchengladbach, Germany Phone: +49 2161 350-2321 Fax: +49 2161 350-2318 [email protected] www.sms-group.com

Mimete begins metal powder production at its Italian facility

Mimete S.r.l., Osnago, Italy, a divi- the powders at its in-house labo- sion of the Fomas Group, Osnago, ratory. Scanning Electron Micro- Italy, has begun production of metal scope (SEM) images of the powder powders in its new and customised produced reportedly showed a VIGA (Vacuum Inert Gas Atomisation) morphology that was spherical and facility. Mimete’s manufacturing plant homogeneous, and the measured has been specifically designed by flowability also met the targets set. Mimete, a division of the Fomas Fomas to serve the Additive Manufac- Maria Guzzoni, Mimete Strategy Group, has begun production of metal turing market and will target various & Special Projects Coordinator, powders at its manufacturing plant in sectors, primarily biomedical, power stated, “We were all very excited to be Italy (Courtesy Fomas Group) generation, aerospace and racing. together for the first atomisation. It According to Mimete, the first was not about scoring the best result, atomisation process was monitored but it was more about getting to the certain level of uncertainty. We were through an advanced production end of the cycle – the starting point incredibly moved to finally see the management system and the alloy for future challenges and improve- successful results of all the hard chosen for the first batch of powder ments. We studied a lot and we were work and the commitment we went was 316L. Production of IN625 well prepared for all scenarios, but through last year.” and F75 is currently ongoing. The we were aware that moving from www.mimete.com company stated that it then analysed theory to reality always implies a www.fomasgroup.com

Höganäs and Dontyne collaborate on while Dontyne Gears will offer its expertise in gearing and system PM gear options for the auto industry design, and manufacturing practices to reduce time and resources and Sweden’s Höganäs AB is working engines and drivelines, continues to promote efficient production. with Dontyne Gears Ltd, Wash- be a major focus for the automotive “As materials and production ington, Tyne and Wear, UK, to offer industry, states Höganäs. Improving techniques continuously improve, automotive manufacturers a range fuel efficiency and increasing the there are many applications that of services with the aim of drasti- driving range of plug-in vehicles benefit from being looked at again cally improving driveline solutions. will be key for carmakers as the to find much simpler and more Through a newly formed coopera- industry evolves into the era of cost-efficient alternatives,” stated tion, the two companies will show- electrification. Mike Fish, CEO of Dontyne Gears. case how lighter Powder Metallurgy “We help car manufacturers and “Car manufacturers will benefit components, with complex designs, system suppliers design, test and greatly when switching to compo- can bring substantial cost savings prototype new, light-weight metal nents made out of PM instead of for car manufacturers and system powder driveline solutions that are a solid steel. We see a number of suppliers in the automotive industry. much better fit for the hybridisation new applications where PM brings Lightweighting, both for electric and electrification of the automotive big advantages, such as weight and and traditional internal combustion industry,” stated Eckart Schneider, inertia as well as noise reduction.” Director Powder Metallurgy Busi- The two companies have now ness Development at Höganäs AB. launched a joint concept develop- “Our cooperation with Dontyne ment towards hybridising a pick-up Gears means we can become even truck to take advantage of PM better partners for our customers gearing and electrical motor solu- in developing and prototyping PM tions. So far, the project is reported components in general and drive- to show promising developments lines in particular.” and could potentially have a large Höganäs brings to the impact on the design-optimised collaboration its knowledge of drivetrains based on Powder Metal- Transmission gears such as this materials and experience of lurgy solutions. can offer cost savings and improved PM component applications for www.hoganas.com performance (Courtesy Höganäs) automotive driveline solutions, www.dontynegears.com

AM has the power to disrupt, enabling innovative product designs and new agile business models

Atherton Bikes is taking advantage of these capabilities to break free from the rigid, labour-intensive conventional bike manufacturing mould. AM gives Atherton Bikes the flexibility to hone their race bike designs, and to make high performance custom bikes accessible to enthusiasts.

To ﬁ nd out more about the capabilities of our AM systems visit: www.renishaw.com/amguide

Renishaw plc Brooms Road, Stone Business Park, Stone, Staffordshire, ST15 0SH, United Kingdom T +44 (0)1785 285000 F +44 (0)1785 285001 E [email protected] www.renishaw.com

Atherton_A4 advert_03-draft.indd 1 10/05/2019 08:48:49 Image Coutesy of SpaceX Aerospace AM Demands Quality Powders

Powder specifications are evolving quickly and so has Consarc’s Vacuum Induction Melting – Inert Gas Atomization (VIM-IGA) equipment. The first Consarc VIM-IGA furnace was manufactured in 1969 and is still producing powder for the aerospace industry today. Consarc furnaces equipped with Anti-Satellite Technology from Atomising Systems Ltd. provide customers with powders that have excellent sphericity, flow properties, and production costs all while improving product yield when compared to traditional inert gas atomization.

Contact us to explore our vacuum melting technologies and to create an atomization system catered expertly to your unique needs. Come visit us at Powdermet 2019 booth 428

Kennametal to be beta customer for ExOne’s new X1 25PRO metal AM system

The ExOne Company, a provider of standard industry powders used in Additive Manufacturing systems and Powder Metallurgy and Metal Injec- services headquartered in North tion Moulding (MIM). Huntingdon, Pennsylvania, USA, “We see Binder Jet technology as revealed its new X1 25PRO™ metal a key enabler for our differentiated, Additive Manufacturing beta system high-performance wear mate- at Rapid + TCT 2019, Detroit, Mich- rials, such as tungsten carbide and igan, USA, in May 2019. The company Kennametal Stellite™ alloys,” stated, The ExOne Company revealed its new also announced Kennametal Inc., a Sherri McCleary, Director of Business X125PRO beta system at Rapid + TCT supplier of tooling and wear resistant Development Additive at Kennametal. 2019 (Courtesy ExOne) solutions located in Pittsburgh, Penn- “Kennametal is uniquely qualified to sylvania, USA, as a beta customer. supply these additive materials and During the beta period, ExOne components, and we’re pleased to another important step towards stated that Kennametal will have the collaborate with ExOne on cutting- integrating industrial 3D printing opportunity to evaluate the X1 25PRO edge technology with the potential to into existing and new produc- system and trial new materials and help us advance from prototyping to tion lines. We are excited to bring processes. The high-resolution serial production.” Kennametal on as a beta user and production machine is said to be John Hartner, Chief Execu- and look forward to beginning the capable of additively manufacturing tive Officer at ExOne, commented, testing programme.” parts in metal, ceramic, and other “Working with innovative, global www.exone.com advanced materials, as well as companies like Kennametal is www.kennametal.com

All Series Debinding and Sintering Furnace Contact:David/Tel:+86-13567416699 Image Coutesy of SpaceX [email protected]/www.hiper.cn for Metal Injection Molding NO.521,Haitong Road,Cixi City,Zhejiang,China Aerospace AM Demands Quality Powders

Powder specifications are evolving quickly and so has Consarc’s Vacuum Induction Melting – Inert Gas Atomization (VIM-IGA) equipment. The first Consarc VIM-IGA furnace was manufactured in 1969 and is still producing powder for the aerospace industry today. Consarc furnaces equipped with Anti-Satellite Technology from Atomising Systems Ltd. provide customers with powders that have excellent sphericity, flow properties, and walking beam continuous graphite hot zone debinding debinding and sintering furnace and sintering vacuum furnace production costs all while improving product yield when compared to traditional inert gas atomization.

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Chinese Ministry of Industry and IT pursues hydrogen fuel development

S SS-SP-RPERPE P China’s Ministry of Industry and Information Technology has reinforced its commitment to develop the country’s SpShpehreicriacla Pl oPwowdedrer hydrogen fuel industry as part of its ongoing effort to promote green energy, according to China Daily. This year, ★ ★ Ti6TAi6l4AVl 4EVL EI, LBI,T B20T,2 T0i,6 T2i462,4T2i,1T0i213023 the development of hydrogen stations for new energy vehi- ★ Inconel 718, 625 cles was included for the first time in Premier Li Kegiang’s ★ Inconel 718, 625 Government Work Report, released in early April. ★ ★ 3163L1,6 1L7, -147P-4HP, HA,1 A001,0 D0,u Dpulepxlex In a recent news conference held in late April by the ★ Co-Cr-W, Co-Cr-Mo, CrCrWMo State Council Information Office in Beijing, Huang Libin, ★ Co-Cr-W, Co-Cr-Mo, CrCrWMo Spokesman for the Ministry, stated, “Hydrogen fuel cell vehicles will coexist and complement fully electric vehicles, jointly meeting the people’s transportation needs.” Both hydrogen fuel cell vehicles and fully electric lithium battery vehicles are important technical routes for new energy vehicles, Huang said, adding that based on their technical characteristics and development trends, fully electric vehicles have so far proved more suitable for passenger cars travelling within the city limits, while hydrogen-powered vehicles suit large commercial vehicles, such as buses and trucks, used over longer distances. Safely storing hydrogen, however, is a key technical challenge for the development of the industry, as is the lack of supporting infrastructure, laws and regulations surrounding the technology. “The Ministry of Industry and Information Technology will carry out demonstration runs of hydrogen fuel cell vehicles together with other depart- Wire Additive ments, with the aim of promoting innovative development Wire Additive in China’s hydrogen energy and fuel cell vehicle indus- ★ Ti6Al4V ELI, BT20,Ti1023 tries,” Huang added. ★ Ti6Al4V ELI, BT20,Ti1023 Japan’s Toyota motor group – one of the first ★ ★ 0.80/1.8.2/1/1.2.6/1/2.6.0/2 d.0ia dmiaemteerter automakers to develop hydrogen fuel cell vehicles – established a joint research institute with Tsinghua University on ★ O ne barr el with 100-300kg ★ One barrel with 100-300kg April 21, 2019, working on hydrogen fuel cell technology. One Spool with 10-25kg On e Spool with 10-25kg On April 22, Toyota partnered with Foton Motor Group and Beijing SinoHytec, a high-tech enterprise focusing on the R&D and industrialisation of hydrogen fuel cell engines. The cooperation will reportedly see the hydrogen- powered buses produced by Foton Motor coupled with Sino-Hytec’s hydrogen fuel cell power system which uses Toyota’s hydrogen fuel cell stack and other components and parts. Xu Heyi, Chairman of BAIC, Foton’s parent company, stated that Foton’s fuel cell bus will serve the 2022 Beijing Winter Olympics. The collaboration between Toyota and Foton is, according to China Daily, expected to extend to a full range of models, including passenger cars, vans, and light and heavy trucks. Meanwhile, at the 2019 Shanghai Auto Show, SAIC Maxus revealed China’s first hydrogen fuel cell passenger car; this model is said to have a driving range of AS9100 D ISO 13485 www.c-semt.com 340 miles (550 km), and reportedly takes just five minutes AS9100D ISO 1348 5 w w w [email protected] [email protected] to refuel from empty to full.

It was stated that steel’s advantage could be Rise of electromobility not a boosted further by the development of new high- and threat to steel demand ultra-high tensile steel grades, which will allow steel to remain a competitive material for electric vehicle During the Handelsblatt Annual Conference on the future production in the long-term. High- and ultra-high of steel, held in Düsseldorf, Germany, March 20–21, 2019, tensile steel grades can be lightweight and tough, and the Handelsblatt Research Institute (HRI) presented a new steel is also comparatively easy to process and recycle. study, commissioned by voestalpine AG, Linz, Austria, on Jan Kleibrink, Head of Economic Analysis at the the role of steel in electromobility. The study found that, Handelsblatt Research Institute, stated, “There are not although the trend toward lightweighting in automotive only economic reasons for using steel in electromo- construction has enabled materials such as aluminium and bility, but also comparatively good life cycle assess- plastic to become established in the automotive industry, ment and safety aspects.” the demand for steel is predicted to remain high or possibly The study drew on current market and vehicle increase as the automotive industry continues to change. production data to surmise its picture of the future for The study was based on secondary analysis of eighty steel in the automotive industry, finding that several sources, as well as interviews with six experts. Among its automotive manufacturers have near-term plans for conclusions, it found that the electromobility sector will vehicle construction in which steel continues to play rely on an intelligent mix of materials in which steel will a key role. It was found that the BMW i5 model will be continue to play a crucial role. Moreover, it was speculated constructed in steel and light alloys from 2021, a shift that the trend in electric vehicle development of reducing from the carbon used in the i3. weight “at any price” is now coming to an end; while In the Tesla model 3, the share of aluminium and carbon-fibre reinforced plastics, for example, are lighter titanium will be reduced in favour of steel. “The share and tougher than steel, they are also significantly more of high-strength steels amongst the steel grades used expensive and harder to recycle, giving steel a cost and in vehicle construction will rise from its current level ecological advantage. of 18% to 30%,” explained Kleibrink, citing preliminary work by the Posco Research Institute. According to the World Steel Association, this would allow vehicle weights to be reduced by between 25–39%, leading to potential savings of 3–4.5 tons of greenhouse gas emissions over a vehicle’s service life. The study found that steel also plays a crucial role in the motor and drive of electric vehicles, with Integrated between 40 and 100 kilos of non-grain-oriented electrical steel reported to be used in the construc- InductIon tion of purely electric vehicles. It was speculated that alloyIng this could increase demand for this magnetically- and atomIzatIon soft material to over a million tons a year in Europe, SyStemS depending on demand. Steel manufacturers were said to be focusing the development of thinner, tougher electrical steels in order to reduce the weight of the motor. However, as the physical limits in this field are believed to have almost been reached, it is thought that in future manufacturers will differentiate themselves primarily through their expertise in bonding, joining and forming Arcast Atomizers are custom built and competitively priced to meet the growing demand to produce high technologies. quality, low cost, technically advanced metal powders In addition, special alloys with a higher silicon and fulfilling the requirements of today’s pioneering aluminium content are capable of reducing heat loss manufacturing processes. in the motor during magnetic reversal by up to 30%. We can supply machines to atomize titanium alloys, Manufacturers with expertise in this segment are super alloys, refractory and reactive metals, and ferrous expected to benefit from the growing electromobility and non-ferrous alloys in high vacuum purged vessels market. By 2025, it was estimated that over 14 million with inert gas replacement atmospheres. electric vehicles may have been sold in the EU alone. We have installed machines all over the world, from According to the study, this is a trend in which steel as 1 kg research furnaces to 1000 kg production units. a material will play an important role, as the dominant ingredient in an intelligent materials mix designed to www.arcastinc.com maximise cost efficiency, sustainability and safety. www.voestalpine.com

mission technology and e-mobility. ZF to build BMW’s new hybrid eight- “With a modular construction using speed automatic transmission in various starting elements, the new-generation hybrid transmission company’s largest ever single order offers a flexible solution which is suitable for all passenger cars – both ZF Friedrichshafen AG, headquar- to pure electric drives, it confirms conventional as well as electric.” tered in Friedrichshafen, Germany, our strategy to focus on plug-in The order from BMW is expected has received a double digit billion hybrids as an everyday solution and to run for a period of several euro order from BMW AG for its to develop attractive products in years. “The order was based on enhanced eight-speed automatic these areas.” the fact that the customer sees transmission, said to be the largest The latest upgraded version of our technology as a sustainable ever single order in the company’s ZF’s eight-speed transmission, drive solution for its vehicles which history. The new transmission will a technology which has been in supports them in achieving CO2 enter series production in 2022 at production since 2009, has been targets. In addition, the possibility ZF’s plant in Saarbrücken, the lead optimised by integrating an elec- to easily change from one transmis- production facility for ZF’s automatic tric drive. The transmission can sion variant to another allows our passenger car transmissions, with be installed in almost all vehicle customer the flexibility to react to production for further customers to classes with a front-longitudinal market requirements.” be undertaken at its locations in Gray drive configuration. “Alongside the significant CO2 Court, USA, and Shanghai, China. “We have consistently optimised savings potential, this high degree “This business win is the largest our eight-speed automatic transmis- of flexibility is resulting in strong single order in the history of ZF,” sion according to future e-mobility interest in our transmission. We are stated Wolf-Henning Scheider, ZF’s requirements,” stated Michael in very promising discussions with CEO. “When it comes to the electrifi- Hankel, member of the ZF Board of other customers,” added Hankel. cation of passenger cars, in addition Management responsible for trans- www.zf.com

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Powering electric vehicles using Ricardo partners water, CO2 and cobalt with Geely to develop Researchers at the University of electricity would then power the Massachusetts Lowell, USA, report system that operates the vehicle’s advanced hybrid that they have developed a new way motor, rechargeable battery and transmission to power electric vehicles by using headlights. water, carbon dioxide and cobalt to “This process doesn’t store any Global strategic engineering produce hydrogen gas on-demand hydrogen gas, so it’s safe and poses and environmental consultancy at low temperature and pressure. no transportation issues, greatly Ricardo plc, Shoreham-by-Sea, The research team is led by Prof minimising the possibility of a fire or West Sussex, UK, has partnered David Ryan, Chemistry Department explosion,” commented Prof Ryan, with Geely Auto Group, a leading Chairman, and believes that its new adding that the hydrogen generated manufacturer of new energy vehi- technology could enable vehicles by the technology is more than 95% cles based in Hangzhou, China, to of all sizes to run for longer while pure. “Hydrogen burns completely develop a new advanced transmis- maintaining zero emissions. clean; it produces no carbon dioxide, sion for range-extended plug-in Because the majority of electric only water. And, you don’t have to hybrid vehicles. vehicles currently in use are powered burn hydrogen to generate electricity. According to Ricardo, the devel- by batteries which must be recharged Hydrogen can be used in fuel cells, in opment approach will be collabo- periodically, and which have which it combines with oxygen from rative and flexible with co-located, limitations such as storage capacity, the air to produce electricity at up to joint teams consisting of Geely the time required to recharge, and 85% efficiency.” and Ricardo engineers based in cost, much current electric vehicle Further, “since hydrogen is not China and the UK. This is expected technology is only practical for small mined or pumped out the ground like to support the internal commu- cars and not for larger vehicles such fossil fuels, we have to produce it,” nications and decision-making as trucks and busses. Prof Ryan, he added. “Current methods of doing processes. however, believes that the technology that are expensive and inefficient. In addition to the core engi- developed by his team could be used This, coupled with the lack of needed neering team, support will also be to power vehicles of all sizes. infrastructure, has hampered the available from Ricardo’s tech- In an electric vehicle using this transition from a petroleum to a nical centres, which are based in technology, all hydrogen created hydrogen economy. Our hope is that various locations around the world, would go directly into a fuel cell, the catalytic hydrogen technology we including the Czech Republic. where it would be mixed with oxygen have developed would help solve all The companies state that the key from the atmosphere to generate of these challenges.” requirements for the transmission electricity and water. The generated www.uml.edu are high efficiency and competitive cost for high-volume A and B-segment products “Ricardo is pleased to have been selected by Geely for this important, new transmission programme,” stated Gary Tan, President of Ricardo Asia. “Geely is one of China’s most respected manufacturers for new energy vehicles, and it is a company that shares the Ricardo ethos of excellence in technology, engineering and innovation. We look forward to working in partnership to deliver this impressive range-extended plug-in hybrid transmission to market in Geely’s future products.” Prof David Ryan (right) and graduate student Ahmed Jawhari examine a proto- www.ricardo.com type of their invention (Courtesy University of Massachusetts Lowell) www.geelyauto.com.hk

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Three new BMW all-electric vehicles undergo testing in Arctic conditions

BMW Group has entered cold testing Starting next year, the BMW of its three new all-electric vehicles, iX3 will feature the fifth generation the BMW iX3, BMW i4 and BMW of BMW eDrive technology for the iNEXT, expected to launch in 2020 first time. This electric motor and BMW electric vehicles undergo winter and 2021. According to the group, it high-voltage storage unit is said to trial tests (Courtesy BMW Group) is currently testing prototypes of the feature state-of-the-art battery cell new models under arctic conditions technology to facilitate purely electric at the winter test centre on Arjeplog, driving in a new dimension. With a nology featured by the BMW i4, with Sweden, situated on the edge of the reported range of over 400 km and a reported range of over 600 km. The Arctic Circle. the possibility to use DC charging BMW i4 will be produced at the BMW Within the framework of compre- stations with a capacity of 150 kW Munich plant from 2021. hensive vehicle testing, the vehicles’ to charge its battery, this Sports The BMW iNEXT will feature drive and suspension components Activity Vehicle (SAV) is reported to be the BMW Group’s future modular are being put to the test under suitable for both day-to-day use and construction system, reportedly extreme weather and road condi- long-distance travel. The BMW iX3 combining innovations in the areas of tions on the icy surfaces of frozen will be the first model produced for design, automated driving, connectivity, lakes, on snow and in very low the entire global market by the BMW electrification and services (D+ACES) temperatures, as the manufacturer Brilliance Automotive Joint Venture defined by the group’s Number One aims to prove the reliability and production unit in Shenyang, China. > Next corporate strategy. The iNEXT performance of the electric motors, The BMW i4 is a four-door coupe also has a reported range of over 600 high-voltage batteries and power positioned in the premium midrange km and will be produced at the BMW electronics of the BMW eDrive segment and will also feature the Dingolfing plant as from 2021. technology. fifth-generation BMW eDrive tech- www.bmwgroup.com

ZF to acquire vehicle braking tion, as the transaction will result in a sustainable strengthening of ZF.” solutions specialist WABCO Jacques Esculier, Chairman and CEO of WABCO, added, “Joining ZF Friedrichshafen AG, Germany, has Wolf-Henning Scheider, ZF CEO, forces with highly respected ZF will entered into a definitive agreement stated, “We believe that, together create a leading global technology to acquire WABCO, a global supplier with WABCO, ZF can form the world’s company well positioned to capitalise of braking control systems, technolo- leading integrated systems provider on future demand for autonomous, gies and services. Together, ZF and for commercial vehicle technology, efficient and connected commercial WABCO state that they will form a creating long-term value and security vehicles. We have a long history of leading global integrated mobility for its customers, employees and successful collaboration to develop systems provider for commercial owners. For ZF the acquisition of a innovative technologies with ZF vehicles. The planned acquisition, at specialist and leader for commer- with both companies sharing an $136.50 per share for a total equity cial vehicle braking systems means uncompromising drive for excellence, value of approximately $7 billion, has adding a stable and growing business passion for innovation, and excep- been approved by ZF’s Management segment and enables our existing tional customer focus.” Board and Supervisory Board and commercial vehicle division to expand The planned acquisition is part WABCO’s Board of Directors. its expertise in vehicle dynamics of ZF’s Next Generation Mobility WABCO’s products and services control.” strategy and will expand the compa- include integrated braking systems “This will create the foundation for ny’s expertise to include commercial and stability control, air suspension ZF to offer comprehensive systems for vehicle braking solutions for the first systems, transmission automation safe and automated mobility solu- time. ZF expects to close the transac- controls, aerodynamics, telematics, tions for passengers and goods to our tion at the beginning of 2020. and fleet management solutions. customers,” he continued. “This is The combined company is WABCO reported €3.3 billion in also in the best interest of our owners, expected to have annual sales of revenues in 2018 and employs some the Zeppelin Foundation and the Dr approximately €40 billion. 16,000 people across forty countries. Jürgen and Irmgard Ulderup Founda- www.zf.com

Toyota makes available nearly 24,000 Weissgärber royalty-free patent licences for vehicle appointed electrification provisional manager of Toyota Motor Corporation has particularly those used in hybrid Fraunhofer IFAM announced that it will grant royalty- electric vehicles (HEVs), that have free licences on nearly 24,000 of its helped Toyota to realise enhanced Dresden patents for vehicle electrification- performance, reduced size and related technologies in an effort to cost reductions. More specifically, Dr Thomas Weissgärber has taken further promote the widespread use the patents included are for parts over the provisional manage- of electric vehicles. The company and systems, such as electric ment of the Dresden branch of also plans to provide fee-based tech- motors, power control units and the Fraunhofer Institute for Manu- nical support to other manufacturers system controls. These are core facturing Technology (IFAM) and developing and selling electrified technologies that can be applied to Advanced Materials IFAM. He vehicles when they use Toyota’s the development of various types of succeeds Prof Bernd Kieback, who motors, batteries, PCUs, control electrified vehicles including HEVs, retires after many years as head of ECUs and other vehicle electrification plug-in hybrid electric vehicles the institute. system technologies as part of their (PHEV) and fuel-cell electric vehi- Dr Weissgärber, a long-time powertrain systems. cles (FCEV). employee of the institute, previ- Toyota stated that it aims to help Together, Toyota stated that ously served as deputy head of governments, automakers, and it will offer approximately 23,740 Fraunhofer IFAM Dresden and has society at large to accomplish goals patents awarded over its more than conducted research in various fields related to climate change. Shigeki twenty years of electrified vehicle of Powder Metallurgy. He is said to Terashi, Member of the Board and technology development, with the have contributed significantly to the Executive Vice President of Toyota grant period beginning immediately development of the institute into one Motor Corporation, explained, “Based and lasting through the end of 2030. of the leading application-oriented on the high volume of inquiries we Contracts for the grants may be research institutes in the field of PM receive about our vehicle electrifica- issued by contacting Toyota and technologies and materials, and to tion systems from companies that discussing specific licensing terms the strengthening of ties between recognise a need to popularise hybrid and conditions. science and applied research. In and other electrified vehicle tech- Toyota already offers 5,680 addition, he is involved in various nologies, we believe that now is the patents related to its FCEVs as committees in the field of PM. time for cooperation. If the number of January 2015. Now, it will add By organising scientific events of electrified vehicles accelerates approximately 2,590 patents related internationally, as well as at the significantly in the next ten years, to electric motors, 2,020 patents Dresden location itself, he reportedly they will become standard, and we related to PCUs, 7,550 patents aims to contribute to the transfer of hope to play a role in supporting that related to system controls, 1,320 knowledge within the field and grow process.” engine transaxle patents, 2,200 the general perception of PM, and The royalty-free patents are charger patents and 2,380 addi- to further strengthen and expand said to be for advanced technolo- tional fuel cell patents. Dresden’s location as a leader in gies found in electrified vehicles, www.global.toyota PM in Europe and worldwide. In November, he was awarded the Skaupy Prize for his achievements to date. Weissgärber stated that he sees his new role as motivation to continuously expand and build on existing competencies at Fraunhofer IFAM Dresden and to utilise the institute’s knowledge, especially in materials, PM and AM, for innovative, future-oriented solutions to generate optimal solutions in core areas such as energy technology, Toyota has released almost 24,000 patents relating to vehicle electrification mobility and medical technology. (Courtesy Toyota Motor Corporation) www.ifam-dd.fraunhofer.de

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to supply local customers with its ZF strengthens its commitment to flagship product for passenger cars, Chinese automotive market as well as variants of the 8HP for plug-in hybrid drives. In the future, ZF Friedrichschafen AG, Germany, “Our strategy for the Chinese ZF stated that it will endeavour to is set to introduce production of its automotive market is called ‘local produce purely electric drives in 8-speed 8HP automatic transmis- for local’,” explained Dr Holger Klein, China; production facilities for this sion to its plant in Shanghai, China, ZF Board Member responsible for are currently under way. as it seeks to expand its presence the Asia-Pacific region, with China Further, to meet local production in the country. The group currently as its core market. “Almost all of our demand for passenger car electric offers its Chinese customers a customers will expand their business power steering systems in China, number of high-tech solutions for in China in the coming years. We ZF is reported to be building a new e-mobility and autonomous driving, will support them in this by offering steering plant in Zhanjiagang – set and is now said to be enlarging its our entire portfolio locally – from to be the largest of ZF’s thirty-two customer base with Chinese manu- development services to local just-in- plants in China to date. ZF will facturers and new mobility providers. sequence delivery.” also serve the commercial vehicle By enabling the development and “We will increase our degree of market more locally from China: manufacture of its complete product localisation in China up to 100% in a joint venture with commercial portfolio within China, ZF hopes to the coming years,” he continued. vehicle manufacturer Foton will see better support the local market. “With our innovations and high- production of ZF’s TraXon automatic The group opened its first Chinese tech products, we will have an even and hybrid commercial vehicle production site in 1994, and now stronger presence in the future.” transmission begin in the near operates thirty-two, with several Introducing production of its future. To support this venture, a joint additional plants planned and 8-speed 8HP automatic transmission production plant has been built south significant expansions to its devel- to the Shanghai plant, where of Shanghai. ZF currently employs opment capacity within the country automatic transmissions have been around 15,000 staff in the country. underway. produced since 2004, will enable ZF www.zf.com

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Höganäs in teardown of plug-in hybrid to establish opportunities for PM

In order to establish a better understanding of the use of Powder Metallurgy components in a modern plug-in hybrid vehicle, a team of engineers from Höganäs China has A team of engineers from Höganäs China is undergoing a project to tear down undertaken a project to tear down a a hybrid SUV (Courtesy Höganäs) BYD Tang DM hybrid SUV. The team in Shanghai dismantled the car to battery pack is said to deliver an The teardown follows on from identify components that are either all-electric range of 80 km (50 miles) a similar project in 2017, where a made using Powder Metallurgy, or from two electric motors, front and team of engineers from Höganäs which could be converted to Powder rear. The Tang has a 2.0 litre internal stripped back three new vehicles Metallurgy production. combustion engine and is fitted with to their component parts. The full The BYD Tang is a plug-in hybrid a Dual Mode (DM) system, allowing report can be read in the Summer crossover sport utility vehicle devel- drivers to switch between all-electric 2017 issue of Powder Metallurgy oped by Chinese automaker BYD. mode (EV mode) and hybrid electric Review magazine. Its 18.4 kWh lithium iron phosphate mode (HEV mode). www.hoganas.com

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EPMA announces new President and Council Members

The European Powder Metallurgy 2022), succeeding Philippe Gunder- Association (EPMA) announced a mann. Pierre Blanchard, Erasteel number of leadership changes during Kloster AB, was elected as EPMA its General Assembly on March 21, Treasurer (2019– 2022), succeeding 2019, in Brussels, Belgium. Every Peter Kjeldsteen, Sintex A/S. three years, the EPMA Statutes During the assembly, outgoing require an election to be held to form EPMA President Philippe Gunder- a new EPMA Council, as well as a new mann reported on PM industry EPMA President and Treasurer (both trends and statistics, highlighting Ralf Carlström, Digital Metal AB, was subject to a maximum of two terms). the various PM sectors. Lionel elected as EPMA President The new EPMA Council was elected by Aboussouan, the EPMA’s Executive a ballot of Full Member companies in Director provided updates on the Keynote speeches, presented advance of the General Assembly for various EPMA projects and activities towards the end of the assembly, the period of 2019–2022, with repre- undertaken by the association during saw Guy Thiran, Executive Director, sentatives of both Pometon SpA and 2018, and Kate Blackbourne, EPMA Eurometaux, provide an update on Polmo Lomianki SA joining the council Congress Manager, gave insight into ‘Regulatory developments of interest for the first time. last year’s Euro PM2018 Congress & to the Powder Metallurgy Industry’, As the tenure of the current EPMA Exhibition. Andrew Almond, EPMA and Prof Thilo Bein, Fraunhofer LBF President and Treasurer came to Marketing Manager, provided an / Chairman for Materials, Design and an end, the newly formed council overview of marketing and promo- Production Task Force, European announced during the General tional work in 2018 and the EPMA’s Automotive Research Partners Asso- Assembly its choice for the EPMA’s new Technical Manager, Bruno ciation (EARPA), discuss ‘Advanced new President and Treasurer. Ralf Vicenzi, explained the various EU Lightweight Design – Challenges and Carlström, Digital Metal AB, was projects the EPMA has been involved Trends’. elected as EPMA President (2019– with during the last twelve months. www.epma.com

Stator design with SMC Sintex publishes PM case studies This case study looks at the benefits of SMC in the production Sintex a/s, Denmark, has published their development was to reduce fric- of stators for cheaper, smaller and a number of Powder Metallurgy case tion during use. Further key benefits more efficient motors. An example studies highlighting the capabilities of the new wear-resistant coating is provided of the production of a of PM technologies for a range of were the achievement of higher stator with an outer diameter of 80 applications. The case studies are friction plate strength and extended mm, length of 20 mm, six stator available on the company’s website lifetime. teeth, outer rotor diameter of 28 in English, German and Danish, and mm and four poles. include the following: Powder Metallurgy fulfils high requirements World-class sound using innova- High strength requirements fulfilled In this case study, Sintex presents the tive SMC solution using MIM development of a custom PM solution Looking at the use of SMCs in a Looking at the use of Metal Injection for an automotive customer with loudspeaker produced by a Danish Moulding (MIM) technology to enable strict material and quality require- speaker manufacturer. SMCs are a customer to fulfil the high strength ments. The customer required higher an attractive solution for applica- requirements of a sensor housing, corrosion resistance without a signifi- tions that require low losses, in in the same geometry as plastic but cant cost increase. Sintex’s case particular at high frequencies, as with the same strength as steel. study examines how the company the advantages of SMCs increase at met this requirement through new higher magnetic frequencies. Surface treatment strengthens joins material development and proposals The loudspeaker produced Looking at the production of a wear- for design enhancements, such that through this collaboration was resistant coating for friction plates the higher material price was offset said to be the first loudspeaker to consisting of a wolfram carbide hard by mass savings, and the develop- contain a magnetic system made metal coating. The friction plates are ment of a fully automatic production of SMC. used in wind turbines and the aim of line. www.sintex.com

soon, even large firms might soon see small but fast Zyfra offers digitalisation market players pass by. solutions to PM industry Citing a 360 Research Reports market study, Zyfra commented that, over the next five years, the Powder Zyfra, a specialist in digitalisation systems focusing on the Metallurgy market will be growing at a solid 3.6% CAGR machinery, metallurgy, mining, oil & gas and chemical in terms of revenue. The global market size will, it was sectors, has reported on the opportunities that the intro- reported, reach $9.72 billion by 2024, from $7.85 billion in duction of such systems could offer the Powder Metal- 2019. lurgy sector. According to the company, headquartered Powder Metallurgy is backed by the needs of several in Helsinki, Finland, the Powder Metallurgy industry has industries, especially the automotive industry. Both have been lagging behind other sectors, such as the auto- been expanding since the 1950s and, nowadays, around motive industry, when it comes to implementing such 90% of Powder Metallurgy products are used in the processes. However, as the demand on data collection transportation market, according to Tadayuki Tsutsui and monitoring options increases, it reports that there from Hitachi Powdered Metals. It means that Powder will be opportunities to embrace digitalisation and imple- Metallurgy can’t ignore various challenges that the ment Artificial Intelligence to improve the Powder Metal- motoring industry currently faces, including, for example, lurgy supply chain. subscription-based access and demand for green vehi- Over the past few years, Zyfra states that the Powder cles. To meet these challenges, Powder Metallurgy has to Metallurgy sector has picked up pace in digitalisation. embrace digital transformation and smart technologies, There have been significant innovations in automation, states Zyfra. data collection and analytics. Companies that are hesitant “AI solutions for casting powder mixtures have been to embark on digital transformation, will have to do it in place for quite a long time, and most of them can be soon, the company reports. According to GKN Powder applied in Powder Metallurgy as well,” stated Konstantin Metallurgy’s Chief Digital Officer, Paul Mairl, such compa- Gorbach, ZYFRA Head of Intelligent Applications. “Those nies will be missing an opportunity and, if they don’t act smart technologies allow you to control the level of consumption and improve production efficiency by better managing the manufacturing process and assessing the product quality.” “They also minimise manual handling and reduce powder contamination, manage data across multiple locations and monitor the production status,” continued y Gorbach. “Smart solutions for Powder Metallurgy are able to develop unique production with set properties for each client and smoother distribution of production capacities. As a result, the producer will offer its customers not just RevolutionaR a product, but a complete solution, a combination of new Results demand RevolutionaRy powdeR alloys with unique properties and engineering solutions for their application.” Due to the efficiency of our cutting- It was stated that usually, during the manufacturing edge technology we can offer the process, a large amount of data is accumulated that POWDER lowest priced powder on the market directly or indirectly affects the quality of the company’s with no compromise in quality. product. Powder Metallurgy is no exception; data is Our powder is: collected and stored for all key processes, from mixing • Spherical ingredients to quality control, including pressing and • Free-flowing • D50 of 35µm for most materials especially the process of sintering. • D50 of 20µm for titanium super alloys “When you connect all meaningful factors together, • Has high tap density you create a model that allows the prediction of mechan- We process directly from: ical properties in the future product, as well as the prob- ability of defects,” continues Gorbach. “If any adjustments • Raw elemental material • Pre-alloyed stock are required, the operator will know about it in advance, • Sponge making it is possible to improve the quality proactively.” • Recycled chip Computer vision technologies make it possible to • Recycled parts automatically distinguish many types of defects. Zyfra is • Over-sized powder reported to be implementing a pilot project whose task • We can handle refractory and reactive alloys is to find defects in plastic manufacturing, but a similar www.arcastmaterials.com technology can be applied to Powder Metallurgy, the ISO 9001:2015 and AS9100D Certified company added. A division of Arcast Inc. www.zyfra.com

Expanding Worldwide

Representation in USA, Europe, Korea, Japan, China, India

Mesh Belt Sinter Hardening Pusher for PM (SS & Fe Parts) TMax 1700 °C Hydrogen Pusher Aluminium Sintering

Walking Beam Powder Annealing Low Temp Pusher Hybrid Porosity Sealing + (Steam Treatment) Nitrocarburising

carcinogen, making it unsuitable for Sino-Euro expands its portfolio of use in medical implants or tools. titanium powders Speaking on the expansion to Sino-Euro’s titanium portfolio, Sino-Euro Materials Technologies Ti6242 is said to offer a Dr Liang Shujin, the company’s of Xi’an Co., Ltd. (SMT), a subsid- highly desirable combination of General Manager, stated, “Based iary of the Northwest Institute for tensile strength, creep strength, on the SS-PREP technique, Non-ferrous Metal Research located toughness and high-temperature Sino-Euro could make any kind of in Xi’an, Shaanxi Province, China, stability for long-term applications titanium alloy into spherical powder has expanded its range of titanium at temperatures of up to 530°C. Its just as easy as Ti-6Al-4V. Unlike the powder with the introduction of primary application area is in gas sophisticated correlation between BT20, Ti1023, Ti6242 and Ti6Al7Nb. turbine compressor components, alloy and parameters during gas The company will produce the new such as blades, discs and or plasma atomisation, SS-PREP materials using its Supreme-Speed impellers. owns the similar parameters Plasma Rotating Electrode Process Ti6Al7Nb is said to offer an for different kind alloy, including (SS-PREP™). ideal substitute for Ti6Al4V in titanium, nickel-based and iron- BT20 titanium alloy, also referred medical applications, as it does based alloy.” to as TA15 in China, is said to be not contain vanadium. Vanadium According to Sino-Euro, its widely used in aerospace engines, has been found to be toxic to powder business achieved revenues nuclear structures and other humans at high levels, and has of around $6 million in 2018. industries in China and Russia. The also been identified as a possible www.c-semt.com nominal chemistry of BT20, with alpha and beta phase comprised of Ti-6.5Al-1Mo-1V-2Zr (weight percentage), reportedly offers excellent mechanical properties at both elevated temperatures and at room temperature. Ti1023 is a TIMET-developed, high-strength, hardenable forging alloy used in airframes, landing gear components and engines. It is said to be suitable for near-net shape forging techniques due to its excellent combination of strength and Sino-Euro has added Ti1023 (left) and BT20 (right) to its portfolio of spherical toughness. metal powders (Courtesy Sino-Euro Materials Technologies of Xi’an Co., Ltd.)

composite materials. The site Plansee Composite Materials manufactures a number of prod- appoints new Managing Director ucts from the group’s tungsten heavy metal alloys, as well as metal Plansee Composite Materials GmbH, successful commissioning in 2013. and ceramic composites based Lechbruck, Germany, part of the At present, Plansee has more than materials such as on titanium and Austrian-based Plansee Group, has 400 employees in China. aluminium. appointed Mathias Hochstrasser as On his appointment to Managing Among other products, Plansee its Managing Director. Hochstrasser Director of Plansee Composite Composite Materials develops has worked for the Plansee Group Materials, Hochstrasser stated, sputtering targets and cathodes for thirteen years, having joined the “Plansee in Lechbruck is very well for hard material coatings. Its company in Switzerland in 2006. positioned – with great employees, Lechbruck site was founded in After joining Plansee as a competitive products, good 1975 and is certified to ISO 9001 Production Planner, Hochstrasser capacity utilisation and outstanding for quality management systems in relocated to China in 2011 as Project machinery.” the development, production and Leader for the construction of a new Plansee Composite Materials distribution of powders, semi- plant. He is said to have managed is Plansee Group’s competence finished products and products and incrementally expanded centre for tungsten heavy metals made of refractory metals. the plant in Shanghai since its as well as metallic and ceramic www.plansee.com

T-EFFETE L China announces new tungsten and rare earth quotas for first half 2019

Roskill Information Services, London, UK, has reported on China’s new rare earth and tungsten mine production quotas for the first half of 2019. In March, China’s Ministry of Natural Resources and the Ministry of Industry and Information Technology set tungsten quotes for the first half of the year at 49.8 kt (65% WO3 basis), while rare earth quotas were set at 50.4 kt of light rare earths and 9.6 kt of medium and heavy rare earths. According to Roskill, the new tungsten quotas has left a degree of uncertainty in the market. Usually, two quotas are given by the ministry – one for mines where tungsten is the primary (or sole) product and a second for mines with tungsten as a by-product. The quota for H1 2019 is said to be some 22% lower than the overall quota for H1 2018 (63.9 kt) and 3% lower than the primary tungsten quota HYDROGEN H NITROGEN N OXYGEN O (51.3 kt), with a 12.6 kt quota also outlined for by-product tungsten in H1 2018. In 2017 and 2018, the overall tungsten quota increased because of a rise in the by-product quota. ON-SITE GAS GENERATION SYSTEM Historically, Roskill added that the quota has lagged FOR A MORE COST-EFFECTIVE AND RELIABLE SUPPLY behind actual mine production; between 2011 and 2018, tungsten mine output exceeded the quota every year. This At HyGear, we differentiate ourselves with our has reportedly been addressed in China’s National Mineral cutting-edge technology of on-site gas generation and recovery of industrial gases. In order to guarantee the Resources Planning (2016–2020) document, which caps reliability of supply, we offer back-up with our own fleet tungsten mine output at 120 kt/year of concentrates on a of trailers and through our global partners. 65% WO3 basis (61.6 kt contained W) by 2020, and is said to be more reflective of production in recent years. Our approach is unique because of our strong technology Despite increasing by nearly 30% compared to the H2 backbone and the way we partner with you as our 2018 quota allocation, the H1 2019 quota for rare earths customer. has caused little uncertainty, as the MIIT has indicated that the H1 allocation will represent 50% of the 2019 annual OUR PROMISE quota. This would result in there being no overall change in the mining quota between 2018 and 2019. Inner Mongolia continues to hold the largest portion of the light rare earth mining quota, with 34.6 kt REO assigned to China Northern Rare Earth Group, which operates the Baiyun Obo mine in Baotou. Rare earth mining in H1 2019 is reportedly expected to COST SAVINGS RELIABLE SUPPLY INCREASED remain far below the quota, particularly in southern prov- SAFETY inces where imports of mineral concentrates and semi- processed products are said to have increased significantly since early 2018. Rare earth concentrates imported by China in 2018 and early 2019 have been sourced largely from Myanmar, the USA and monazite concentrates imported from Russia, Brazil and other Asian countries. Rare earth production from imported concentrates and

CO2 REDUCTION NO SURPRISES GLOBAL SUPPORT compounds is not included in separation quotas for RE companies and also avoids the resource tax applied to Chinese domestic mining of rare earths. Contact us today to find out how. Roskill’s full report on Rare Earth: Global Industry, Europe: +31 88 9494 308 | [email protected] Asia: +65 6909 3064 | [email protected] Markets and Outlook was published in December 2018. www.hygear.com Both the company’s Tungsten and Rare Earth reports are available to download via its website. www.roskill.com

Dr Leo Prakash posthumously awarded 2019 Ivor Jenkins Medal

The UK’s Institute of Materials, cialisation of several alternatives to Minerals and Mining (IOM3) has pure cobalt and laid the foundation named Dr Leo Prakash the recipient for the wave of recent research into of its 2019 Ivor Jenkins Medal, and development of low cobalt and posthumously. The annual award is cobalt-free hardmetals, an important presented to individuals in recogni- topic considering the status of cobalt tion of a significant contribution as a critical raw material as well that has enhanced the scientific, as the current strict classification industrial or technological under- issues. standing of materials processing From the mid-late 1980s and into Dr Leo Prakash has been awarded or component production using the 1990s, his fundamental studies the 2019 Ivor Jenkins Medal, posthu- Powder Metallurgy and particulate into the mechanisms of grain growth mously materials. inhibition and sintering of the very Dr Prakash, who passed away finest grained tungsten carbide aged sixty-nine in February 2019, hardmetals at the time were also of European hard materials group was a renowned authority in the great significance for the industry, as within the European Powder field of cemented carbides and were his studies of material proper- Metallurgy Association (EPMA). He other hard materials. His pioneering ties and performance in both labora- authored or co-authored over forty work in the late 1970s and early tory tests and practical applications. publications in international jour- 1980s on iron-based binders for For the last ten years, Dr Prakash nals, conferences and textbooks. hardmetals led to the commer- was Co-chairman of EuroHM, the www.iom3.org

Huacheng Moulding (Changshu)Professional Co., Tooling Ltd. Maker for POWDER METALLURGY since 1978

Taiwan (HQ) www.moldmaker.com.tw [email protected]

China www.szhcjm.com [email protected]

European Office [email protected]

Temperature TAT Technologies 2046°F announces August Copper Layer dates for its sintering courses

TAT Technologies has announced August 2019 dates for its sintering courses, held at the company’s training centre in St. Mary’s, Pennsyl- Copper Diffusion vania, USA. The courses are aimed at The course will explain what happens inside a PM part as it proceeds through employees in the Powder Metallurgy the furnace (Courtesy TAT Technologies) industry who want to learn more about the necessary fundamentals of the sintering process. be properly and thoroughly delubed, students how to guide their well- oxide reduced and graphite diffused, prepared part through the furnace Course 1: Preparation for Better before proceeding to the sintering and achieve a quality sintered result Sintering section of the furnace. with the least property variation and August 20–23, 2019 at higher production rates. Course Course 2: Sintering-Ferrous PM one is a pre-requisite for this course. Covering all aspects of prepara- August 26–29, 2019 tion of parts and the furnace before An Early Bird Discount is available sintering, this course will give Building on the knowledge and skills until June 28, with savings of $1000 attendees a clear understanding of gained in Preparation for Better for students attending both courses. what is needed to ensure parts will Sintering, this course will teach www.tat-tech.com

PM China 2019 concludes after another successful event

The 12th Shanghai International mechanical equipment, Additive Exhibition for Powder Metallurgy, Manufacturing, testing instru- Cemented Carbides and Advanced ments, gas and process solutions. Ceramics (PM China 2019) was held Approximately 210 equipment at Shanghai World Expo & Conven- companies, accounting for 45% of The PM China 2019 exhibition hosted tion Center, China, March 25–27, exhibitors, exhibited at the show, 464 exhibitors, a rise of 11% over the 2019. The organisers reported that as well as 114 material suppliers, previous year the exhibition hosted 464 exhibi- accounting for 24%; approximately tors, a rise of 11% over the previous 120 product companies, accounting year, and welcomed 22,637 visitors for 26%; and approximately twenty across the four days of the event, an Additive Manufacturing companies, tional Injection Molding Forum, the increase of 19.5% over last year. accounting for 5%. Academic Annual Meeting of China Exhibiting companies were A number of academic forums Powder Metallurgy Alliance & 2019 present from a large number of and exchange meetings were also Shanghai International Powder countries including China, the USA, held at the show, including the 2019 Metallurgy Forum, and more. Germany, the UK, Italy, France, the China Summit Forum on Cutting- The 13th Shanghai International Netherlands, Sweden, Switzerland, edge Technology Application and Exhibition for Powder Metallurgy, Austria, Russia, Canada, Japan, Development in Advanced Ceramic Cemented Carbides and Advanced South Korea, Poland, Singapore, Industry & Academic Annual Ceramics will be held at the Shanghai India, Hong Kong and Taiwan, Meeting of the Industrial Ceramics World Expo & Convention Center covering various fields such as Committee of Chinese Ceramic from March 24–26, 2020. powder raw materials, products, Society, The 8th Shanghai Interna- www.en.pmexchina.com

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ls ateria ntaCt m © 2019 Inovar Communications Ltd Co Summer 2019 Powder Metallurgy Review 51 tals ◊ y me Ctor efra s ◊ r metal iCs ◊ eram al ◊ C Hardmet Buying and selling powder metal Recycling Buying and selling Recyclingand furnace scrap powder metal andRecyclingpowderworldwide, furnace since metal1946. scrap worldwide, since 1946. powderpowderandRecycling furnace metal metal andscrap furnace and furnace scrap scrap powderworldwide,worldwide, since since 1946. 1946.metal and furnace scrap powderworldwide, since metal 1946. and furnace scrap worldwide, since 1946.

1403 4th St. • Kalamazoo MI USA • 49001 th 1403 4 St. • Kalamazoo MI USA • 49001 Mailing: PO Box 2666 • Kalamazoo MI USA• 49003 th Mailing: PO Box 2666 • Kalamazoo MI USA• 49003 Call1403 toll- 4 th4 free,St. St. • KUSA: alamazoo• Kalamazoo 1-800- MI31 3-9672USA MI • 49001 USA Outside Mailing:• 49001 USA/Canada: Mailing: 1-269-342-0183 Call toll-free, USA: 1-800-313-9672 Outside USA/Canada:Fax:PO 1-269-342-0183Box 1-269-Box 2666 2666342-0185 • Kalamazoo • Kalamazoo MI USA• MI 49003 USA• Call 49003 toll- Call toll- free, USA: 1-800-313-9672 Fax: 1-269-342-0185 Contactfree, USA:thth Robert 1-800- Lando313-9672 1403Outside1403 44 USA/Canada: St. St. • K• alamKalamaz 1-269-342-0183ooaz MIoo USA MI USA • 49001 • 49001 Email:Outside roberth USA/Canada:[email protected] 1-269-342-0183 M1403Fax:Mailing:ailing: 1-269-342-0185 4 PO St.PO B• ox BKox alam2666 2666 az• Kooalam • K MIalamazoo USA azooMI •US 49001 MIA• 49003 USA• 49003 Contact Robert Lando Call toll-free, USA: 1-800-313-9672 Outside USA/Canada: 1-269-342-0183 CallFax: toll- 1-269-342-0185free, USA: 1-800-313-9672 Outside USA/Canada: 1-269-342-0183 Email: [email protected] MContactFax:ailing: 1-269- Robert PO342-0185 B oxLando 2666 • Kalamazoo MI USA• 49003 Fax:Call toll-1-269-free,342-0185 USA: 1-800-313-9672 Outsideaceironandmetal.com USA/Canada: 1-269-342-0183 Email:Contact [email protected] Robert Lando Fax:Contact 1-269- Robert342-0185 Lando aceironandmetal.com ContactEmail: [email protected] [email protected] Lando aceironandmetal.com Email:Contact rober [email protected] Lando Email: [email protected] aceironandmetal.com aceironandmetal.com 2017 Spring PMR advert ACE.indd 1 21/02/2017 14:36:58 aceironandmetal.com aceironandmetal.com | contents page | news | events | advertisers’ index | email | Industry News

Gopinath named as Fellow of PMAI

During APMA 2019, the 5th Inter- unique processes and world-class national Conference on Powder furnaces for Powder Metallurgy, Metallurgy in Asia, held in Pune, making these available in India India, February 19-21, N Gopinath, and around the world, and for his Managing Director of Fluidtherm efforts that made PMAI an inter- Technology and past-president of nationally respected body,” stated the Powder Metallurgy Association Aniket Gore, President of PMAI. of India (PMAI), was conferred with Fluidtherm is a manufacturer the title Fellow of PMAI (FPMAI) of sintering and heat treatment for his service to the Indian PM furnaces, as well as fluidised bed N Gopinath, Managing Director Buying and selling industry. reactors and chemical/mineral of Fluidtherm Technology, was Fellowship of the PMAI is processing plants. In addition to conferred with the title Fellow of conferred upon individuals who have facilities for plant design, procure- PMAI (FPMAI) for his service to the demonstrated significant contribu- ment, manufacture, start-up and Indian PM industry tions to the science and practice after service, Fluidtherm operates powder metal of Powder Metallurgy, the growth a versatile thermal processing test of the Indian PM industry and the facility where process and product trouble shooting and contract R&D Recycling Buying and selling growth of PMAI. development, as well as client are carried out. “Gopinath has met these services such as failure analysis, www.pmai.in Recyclingand furnace scrap criteria in abundance by developing process selection/optimisation, www.fluidtherm.com powder metal andRecyclingpowderworldwide, furnace since metal1946. scrap worldwide, since 1946. Recycling powderpowderand furnace metal metal andscrap furnace and furnace scrap scrapEPMA announces PM Life training Hot Isostatic Pressing powderworldwide, since 1946. metal and furnace scrapcourse dates for 2019–20 TBC, 2020 worldwide, since since 1946. 1946. Course details to be confirmed by powder metal and furnace scrap The European Powder Metallurgy Powder and Hardmetals the organisers worldwide, since 1946. Association (EPMA) has announced June 3-7 2019 - Sweden worldwide, since 1946. upcoming course dates for PM Life The Powder and Hardmetals Additive Manufacturing in 2019-20. PM Life is a training module will provide a comprehen- August 26-30 2019 – Germany programme organised by a variety sive overview of the fabrication The Additive Manufacturing module of partners in the European PM and use of metal powder and hard will begin with a general introduc- industry, which aims to provide life- metals. The module will cover tion to AM of metals, ceramics and long learning in Powder Metallurgy. both fundamental aspects of the polymers as well as the funda- PM Life delivers comprehensive technology and industrial practices, mental aspects of the industry. training to participants, who have the in sessions led by experts from choice of attending the full five-week academia, research and industry. Metal Injection Moulding course or picking specific modules September 9-13 2019 – Spain which relate to their field of interest. Press and Sinter The Metal Injection Moulding (MIM) 1403 4th St. • Kalamazoo MI USA • 49001 Each one-week course module June 17-21 2019 – France module will include both funda- th 1403 4 St. • Kalamazoo MI USA • 49001 Mailing: PO Box 2666 • Kalamazoo MI USA• 49003 will be hosted in a different venue The Press and Sinter module will mental and practical aspects of Call toll-4th4free,th USA: 1-800-313-9672 Outside USA/Canada: 1-269-342-0183 across five European countries, go into both fundamental and Powder Injection Moulding (PIM) Mailing: PO Box 2666 • Kalamazoo MI USA• 49003 1403 St. St. • K alamazoo• Kalamazoo MI USA MI • 49001USA Mailing:• 49001 Mailing: offering participants a wide range practical facets of the conven- Fax: 1-269-342-0185 technology, from part and mould Call toll-free, USA: 1-800-313-9672 Outside USA/Canada:PO 1-269-342-0183Box Box 2666 2666 • Kalamazoo • Kalamazoo MI USA• MI 49003 USA•Call 49003 toll- Call toll- of experience and contacts within tional powder processing route design, to powder and feedstock free, USA: 1-800-313-9672 Fax: 1-269-342-0185 Contactfree, USA:thth Robert 1-800- Lando313-9672 the European Powder Metallurgy comprising pressing and sintering development, to debinding and 1403Outside1403 44 USA/Canada: St. St. • K• alamKalamaz 1-269-342-0183ooaz MIoo USA MI USA • 49001 • 49001 Email: [email protected] industry. An optional internship is operations. Sessions will be held sintering. OutsideMailing:th PO USA/Canada: Box 2666 • K alam1-269-342-0183azoo MI USA• 49003 Contact Robert Lando M1403Fax:ailing: 1-269-342-0185 4 St.PO • BKoxalam 2666azoo • K MIalam USAazoo • 49001 MI USA• 49003 also offered by PM Life, which can on topics including modelling, the Call toll-free, USA: 1-800-313-9672 Outside USA/Canada: 1-269-342-0183 be undertaken in either a factory or numerical design of parts and tools The EPMA is the acting point of CallFax: toll- 1-269-342-0185free, USA: 1-800-313-9672 Outside USA/Canada: 1-269-342-0183 Email: [email protected] MContactFax:ailing: 1-269- Robert PO342-0185 B oxLando 2666 • Kalamazoo MI USA• 49003 university, so that participants can for pressing, pressing machines, contact for enquiries regarding the aceironandmetal.com practice what they have learnt during material selection, types of Fax:CallEmail: toll-1-269- [email protected],342-0185 USA: 1-800-313-9672 Outside USA/Canada: 1-269-342-0183 course and for registration. Further Contact Robert Lando the course in a working environment. sintering process, the mechanical information and course details are Fax:Contact 1-269- Robert342-0185 Lando aceironandmetal.com Email: [email protected] The PM life training programme is properties of sintered steels and available via the PM Life website. ContactEmail: rober [email protected] Lando aceironandmetal.com made up of the following modules: more. www.pmlifetraining.com Email:Contact rober [email protected] Lando Email: [email protected] aceironandmetal.com © 2019 Inovar Communications Ltd Summer 2019 Powder Metallurgy Review 53 aceironandmetal.com 2017 Spring PMR advert ACE.indd 1 21/02/2017 14:36:58 aceironandmetal.com aceironandmetal.com Industry News | contents page | news | events | advertisers’ index | email |

Formnext + PM South China: A new extensive global network of branch and sales offices, it was stated that trade show for AM and PM the new trade show will be widely promoted on relevant national and The first ever Formnext + PM South China region.” The Greater Bay Area international media channels, online China trade show for the Addi- around Shenzhen is said to be a key portals and social media. Exhibi- tive Manufacturing and Powder location for innovation in science, tors are also expected to benefit Metallurgy industries will be held in technology, electronics, manufac- from Uniris’ experience in markets Shenzhen, China, from September turing, automotive manufacturing, related to the PM industry. 9–11, 2020. Organised by Mesago robotics and automation in China, Formnext + PM South China will Messe Frankfurt GmbH, Germany, and a major driver for the economy. target visitors from a wide range Guangzhou Guangya Messe According to Sascha Wenzler, Vice of sectors, including architecture, Frankfurt Co Ltd, China and Uniris President for Formnext at Mesago automation, automotive, aerospace, Exhibition Shanghai Co Ltd, China, Messe, added, “Formnext has been construction, dental technology, the new trade show will showcase a resounding success in Europe and home appliances, electrical engi- the metal powder industries to an we are confident that the combination neering and electronics, packaging international audience. of Additive Manufacturing, materials, technology, medical technology and Petra Haarburger, Managing and innovative process technologies toolmaking. The event will be held Director of Mesago Messe, the will also perfectly address the current at the Shenzhen World Exhibition organiser of the annual Formnext and future needs of the Chinese and Convention Center, which is show in Frankfurt, stated, “Form- manufacturing industry.” currently under construction and next + PM South China offers both Uniris Exhibition Shanghai Co which, when completed, is expected Chinese and international additive Ltd previously organised the Powder to be one of the largest exhibition manufacturers an exceptional plat- Metallurgy Expo South China. With centres in the world. form in the highly dynamic southern the support of Messe Frankfurt’s www.messefrankfurt.com

INFO: VDW – Generalkommissariat EMO Hannover 2019 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Tel.: +49 69 756081-0 · Fax: +49 69 756081-74 [email protected] · www.emo-hannover.de

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R&D programme launched for Powder Metallurgy helical gears mG miniGears Spa, Padova, Italy, a reducing slots in the gear body). The manufacturer of precision parts, drive combination of these requirements components, gear kits and complex means that a new approach must be system solutions and a company taken to the design of compaction of hGears Holding GmbH, has tooling for the gears’ production. launched a research & development A first prototype has been programme to investigate the use of produced by the company Powder Metallurgy for the production which reportedly meets these of helical gears. The programme will requirements. To increase its aim to expand the advantages of PM knowledge of the stress and strain The prototype PM helical gear technology to the most demanding level of the tool, the company produced by mG miniGears automotive applications, where low utilised strain gauges on the critical Noise Vibration Harshness (NVH) elements. The information gathered properties are requested. by this method will be used for the According to the company, PM next generation of the tool, where and geometrically complex gear. helical gears are characterised by the helix angle of the gear teeth will By drawing on its knowledge and elements that must be produced be increased to the maximum value technology for gear manufacturing, with helical motion movement of the currently used in the industry. mG miniGears expects to be punches, and elements where this The main outcome of this research able to meet the highest quality movement is not allowed (typically programme is expected to be the requirements with its helical gears. a splined central hole or weight- production of a cheap, light, strong www.hgears.com

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The Powder Metallurgy market in India: Potential for continued growth as auto industry advances

India produced a total of 31 million vehicles last year, including passenger and commercial vehicles as well as three and two-wheelers, making it the fourth largest automotive manufacturer in the world. Domestic sales and exports are increasing year-on-year, with the country offering huge potential for growth. The domestic market for sintered components is growing at a CAGR of 22%, with many businesses reporting further investment and new product lines. In this review, Kadambari Gopinath, Fluidtherm Technology, reports on the current state of India’s automotive market and provides an insight into the country’s growing PM industry.

The inflection point for the Indian affected by this, the automobile to a modest 6.3% growth compared Powder Metallurgy industry came sector bounced back and enjoyed to FY 2018 (the Indian financial year at the turn of the century, driven peak production in 2018, reporting runs from April 1 to March 31 of the by general economic growth, an 14.8% growth year-on-year. However, following year. Therefore FY 2019 opening up to foreign investments after a seemingly strong first quarter, refers to the period from April 1, 2018 in the automobile sector through production rates for FY 2019 dropped to March 31, 2019). a Foreign Direct Investment (FDI) programme, and the introduction of emission standards by the govern- World ranking of India’s automotive sector (2018) ment. Since then, the fortune of the country’s PM industry has been strongly interwined with that of its automobile sector, which today 1 1 1 6 7 accounts for around 80% of all PM + + + + Seventh Largest Largest Largest largest sales in the country. two three Sixth tractor largest car commercial wheeler producer wheeler producer producer vehicle producer producer India’s automotive sector

The automobile industry in India has Overall, the shown strong growth over the last three years, in spite of a temporary fourth largest upset following demonetisation in manufacturer November 2016, where the govern- = 4 of vehicles ment of India effectively removed 86% of cash from circulation in an effort to tackle tax-free cash, known Fig. 1 India’s automotive industry is the fourth largest in the world, with in India as ‘black money’. Although capacity for significant growth

Fig. 2 India’s auto industry is working to meet BS-VI (Euro-6 equivalent) emission standards, due to come into force in April 2020 (Courtesy Mahindra Group)

The country’s automobile asso- This slowdown could not have The problem is not technology. ciations have forecast single-digit come at a worse time. Automo- Many Indian manufacturers have domestic sales growth of around bile manufacturers are currently been exporting vehicles and parts 3–5% in FY 2020, owing to a host facing an enormous challenge in to Europe, which has the same of factors including high interest transitioning to the BS-VI emission emission requirements (BS-VI is rates on loans, rising commodity standards (which will come into similar to Euro-6). The challenge prices and poor monsoons force from April 1, 2020) from the is in modifying these technologies (resulting in lower agricultural current BS-IV standards, having to suit an Indian market which output). The outcome of parlia- skipped BS-V altogether. While new demands smaller and lighter vehi- mentary elections in May, and the models are easier equipped to meet cles, smaller engines, and where monetary policies that follow, will BS-VI requirements, the challenge fuel efficiency and cost are critical also affect vehicle sales. lies in upgrading existing models. factors in the purchase decision.

Vehicle production trends in India Domestic sales by vehicle type (2018-2019)

35,000,000 30,915,420 29,094,447

30,000,000 25,330,967 24,016,599 Two wheelers 23,358,047 (80%) Passenger 25,000,000 21,500,165 vehicles (13%) 20,000,000

Three 15,000,000 wheelers (3%) 10,000,000

Commercial 5,000,000 vehicles (4%) 0 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 Fig. 3 Auto production, including passenger and commercial Fig. 4 Two-wheelers account for the vast majority of vehicles as well as two and three wheelers (Courtesy SIAM) automobilesTwo wheelers soldPassenger in India vehicles (CourtesyThree wheelers SIAM)Commercial vehicles

Small capacity diesel engines (less than 1.5 litre) also appear to have taken a major hit. Maruti Suzuki has announced that it will phase out its diesel models by April 2020. The increase in costs to make these cars BS-VI compliant, especially in the small car segment, would price them out of the reach of their buyers. Mahindra & Mahindra will discontinue its 1.2 litre diesel lines, while continuing to sell its higher capacity diesel engine variants. Tata Motors will also close down production of the 1.05 litre diesel engine that drives two of its recently launched hatchback and compact sedan models. However, in spite of this uncertainty in the short-term, the Indian automobile industry remains the fourth largest in the world, and significant growth is seen as Fig. 5 The production of two-wheelers accounts for 80% of India’s domestic inevitable. vehicle sales (Courtesy Yamaha India)

The automotive market in Passenger vehicle Market Leading Market India category share manufacturers share (in (sales vol) (in category) category) Domestic sales (across all vehicle categories) account for about 85% Maruti Suzuki 62.85 % of India’s total vehicle production. Hatchbacks 33% Hyundai Motors 21.2% Most automobile manufacturers Tata Motors 11.2% prefer to set up production facilities in India to combat high import Maruti Suzuki 57.9% duties. Compact sedans 17.6% Honda Cars 19.4%

The two-wheeler market Hyundai Motors 8.6% contributes 80% of total domestic Maruti Suzuki 26% vehicle sales by volume Honda Cars 23.1% India is the largest market for two- Mid-sized sedans 7.1% wheelers in the world, and produc- Hyundai Motors 22.3% tion in this sector grew by 4.86% in Maruti Suzuki 47.9 % FY 2019, compared to the previous year. Two-wheelers constitute Compact SUVs 13.2% Tata Motors 16.7% a large percentage of vehicles Ford India 14% exported out of the country. India has eleven motorcycle Mahindra & Mahindra 42.7% Executive & mid- and seven scooter manufacturers. 14.7% Hyundai Motors 34.1% Motorcycles contribute about sized SUVs Maruti Suzuki 10.3% 63% of total two-wheeler sales, scooters about 33% and mopeds Maruti Suzuki 68.2% less than 5%. Rural markets are MPVs and vans 14.4% Toyota Kirloskar 21.8% dominated by the sales of sub 110 cc two-wheelers. The biggest Mahindra & Mahindra 8.2% growth in the urban areas has been in the mid-capacity segment Table 1 Market share for automotive vehicles in India, highlighting top three (250-500 cc). manufacturers in each category (Courtesy SIAM/Economic Times)

Fig. 6 The market for three-wheelers in India remains Fig. 7 India is the largest producer of tractors in the world strong, with manufactures now also offering electric (Courtesy Mahindra Group) versions (Courtesy Piaggio)

Passenger vehicles account for Motors is the dominant player in this manufacturers are at the forefront 13% of domestic sales volumes segment and accounts for 44.2% of this technology. Two-wheeler This category was negatively of the market. Mahindra & Mahi- giants like Hero, TVS Motors and impacted in FY 2019. Hatchback ndra accounts for 22.6% and Ashok Honda have all launched their sales are the largest and most Leyland accounts for 16.8%. Other variants of electric scooters. There competitive; India is the largest major players include Force Motors are also a number of start-ups who producer in the world of cars less (7.8%) and Eicher Trucks & Buses have entered the electric scooter than 3600 mm in length (Segment A (5.8%). market such as Ather Energy, cars). Maruti Suzuki is the market Okinawa and Avon. leader (51% marketshare), followed Three-wheelers maintain popularity The electric three-wheeler by Hyundai Motors (16.1%), Mahi- Sales of three-wheelers increased by segment is also gaining ndra & Mahindra (7.5%) and Tata 10.27% in FY 2019, when compared to momentum. Mahindra and Lohia Motors (6.8%). Honda Cars, Toyota the previous year. Passenger carrier Auto both have electric three- Kirloskar and Ford India have sales registered a growth of 10.62% wheelers. Piaggio has announced smaller shares. It was a tough year in this period, up from the previous the launch of its electric three for Renault, Nissan Motors and year, and goods carriers grew by wheeler this year. However, the Volkswagen, who reported signifi- 8.75%.The market leader in this charging infrastructure, high prices cant drops in sales in the country. segment is Baja Auto, followed by and lack of subsidies are some of Luxury cars accounted for about Piaggio and Mahindra & Mahindra. the issues that plague widespread 1.2% of the total domestic sales in adoption of electric vehicles. FY 2018. Mercedes Benz has the Exports of Indian-manufactured The passenger vehicle segment largest share (38%), followed by vehicles see steady growth has been lagging behind with BMW (26%). Others include Audi, In FY 2019, the export of auto- Mahindra & Mahindra being the Jaguar, Volvo and Porsche. mobiles manufactured in India only manufacturer which offers accounted for $18.2 billion and 15% fully electric vehicles (EVs) in the Commercial vehicles demonstrate of total automobile production in the country. robust growth country. Exports increased from the “India is not ready for electric Sales of commercial vehicles previous year in all segments except vehicles. I see hybrid and CNG increased by 17.5% in FY 2019 passenger vehicles. vehicles more in public transport compared to the previous year, (buses),” stated Sharath Vijayra- crossing the one million mark. Electrification of vehicles lags ghavan of Sundaram Motors. It is Medium & Heavy Commercial behind expected that the transition from IC Vehicles increased by 14.6% and The government of India has set a engines to electric vehicles in India Light Commercial Vehicles grew difficult target of 30% of all vehicles will only really pick up speed by by 19.46% in the same period. Tata to be electric by 2030. Scooter about 2025.

PM components in India’s automotive sector

The total tonnage of PM parts manufactured in India in FY 2019 was approximately 38,000 tons. The domestic market for sintered components is growing at a CAGR of 22% and is expected to reach US $275 million in FY 2020. Approximately 20% of PM components manufactured in the country are exported. The percentage of sintered parts in a vehicle still remains low when compared with global averages. While Japan and Europe are estimated to have 12 kg of sintered parts for every vehicle, India has a mere 4 kg per vehicle. This represents a Fig. 8 Applications for PM include components in synchroniser systems huge opportunity and keeps PM part (Courtesy Sintercom India) manufacturers optimistic.

Increase in the use of PM parts to meet BS-VI emission standards machining,” stated Jignesh Rawal of as lightweighting and fuel efficiency Indian PM part manufacturers are Sintercom India. BS-VI also requires will become key points of discussion excited by opportunities arising reductions in noise, vibration and with OEMs. from BS-VI standards, which require harshness (NVH). This could drive monitoring and control of tailpipe conversion from conventional forged Reduced popularity of diesel emissions of pollutants in running to sintered components. Compo- engines impacts Indian PM part conditions. This translates to a signif- nents such as mass balancers and manufacturers icant increase (more than double) in anti-backlash gear drives are already In FY 2018, around 40% of engines the number of sensors being used, produced by sintering. produced in the country were both before and after the catalytic The CAFE (Corporate Average diesel. However, this is expected to converter. “The sensor holder is a Fuel Economy) norms, expected change significantly in the coming part that is perfectly suited for manu- to come in 2022, will create more years. With the new BS VI standards facture through PM as opposed to opportunities for PM manufacturers coming into play from April 1, 2020,

Market share of diesel engines in India

60% 58% 53% 48% 48% 50% 44% 40% 39% 37% 40% 36% 32%

26% 30% 25% 24% 21%

20% 15%

10%

Percentage of vehicles with diesel engines of vehicles Percentage 0% 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019e 2020e 2021e 2022e Reporting year

Fig. 9 Penetration of diesel engines in the Indian market (Courtesy ICRA Research)

Introduction of TGDI technology will also become mainstream in the compact SUV segment – a very popular category in the country. Turbo- chargers will be used by OEMs to reduce the overall weight of vehicles. These trends are good news for PM manufacturers, who expect to see a positive impact on production volumes.

Variable Valve Timing (VVT) Currently, all major OEMs meet BS-IV standards without using VVT systems in their engines. This will not be possible when the country switches to BS-VI. Petrol engines are being equipped with single or dual VVT/ VCT to meet emission standards. VVT is expected to add 1 to 2.7 kg of PM components per vehicle by 2020, depending on which component manufacturer you talk to. Fig. 10 Powder Metallurgy is used to manufacture ABS sensor rings (Courtesy Sintercom India) Local sourcing remains key Due to the price sensitivity of the Indian market, automotive suppliers are working closely with part manu- Vehicle category Average local sourcing in top selling facturers to source high levels of models (with > 80% market share) locally produced components. To Hatchbacks, compact sedans, SUVs 90–95% further encourage this localisation, Premium sedans 98–90% the government recently introduced its Commercial vehicles > 90% FAME (Faster Adoption and Manufac- turing of hybrid and Electric Vehicles) 2 wheelers > 90% II Initiative. Under this scheme, incen- Tractors > 95% tives are available to makers of EVs where local sourcing exceeds 40% of Table 2 Tier 1 levels of locally sourced components across vehicle segments the ex-factory price of electric buses (Source: IHS, McKinsey) and 50% for all other categories. The increased need for local sourcing for the two-wheeler and many automobile manufacturers Emerging opportunity for turbo- commercial vehicle segments also are revisiting their portfolio. OEMs charged compact petrol engines offers a key opportunity for Indian PM have already stopped manu- In India, while over 90% of diesel part manufacturers. facturing small capacity diesel engines are equipped with turbo engines (less than 1.5 litre). Close chargers, very few petrol engines High-density parts needed to a dozen small diesel cars have have them. There is, however, a shift To date, the Indian auto market has been discontinued. to Turbocharged Gasoline Direct demanded PM parts with densities of PM part manufacturers with Injection (TGDI) from Multi Port Fuel around 7.2 g/cm3 or less. However, a product portfolios heavily skewed Injection (MPFI) technology to boost new wave of localisation is expected to diesel engine components power. to increase the demand for higher (turbochargers for diesel engines, At the moment, there are only density parts. Many part manufac- fuel injection systems, diesel two manufacturers that offer three- turers have already invested in plant filters, etc.) have been signifi- cylinder engines, namely Ford & GM. and machinery to manufacture compo- cantly affected. However, if OEMs However, companies such as Hyundai nents with densities of up to 7.4 g/cm3, continue to focus on high capacity are looking to launch more fuel and one PM manufacturer reported diesel engines in newer models, efficient turbocharged petrol engines that it has been achieving 7.6+ g/cm3 the diesel PM component market is for their compact hatchbacks and densities as it caters to a large export expected to recover. sedans. market. However, the consensus is

Fig. 11 This magnet housing, used in the assembly of Fig.12 Couplings, such as this manufactured by Pricol electromagnetic clutches and brakes, won Best PM India, are used in agriculture and industrial water Product Award at APMA 2019 (Courtesy Speciality pumps to couple motor and pump assemblies (Courtesy Sintered Products) Pricol India)

that PM parts with densities greater Electrification of vehicles Many PM part manufacturers have than 7.4 g/cm3 are mostly imported at Nine of the ten most polluted expanded their product portfolio to the moment, and this market offers cities in the world are in India, and cater to the electric vehicle segment. a good opportunity for Indian PM part the Indian government is betting Niranjan Nalkhade of Speciality manufacturers. heavily on electric vehicles to Sintered Products says that his counteract this. It has developed company has added three EV parts to Growing demand for automatic trans- a framework to expedite the its portfolio and, in addition, its R&D missions purchase of electric vehicles for team is working on creating entire The use of automatic transmissions public transport and official use in solutions for electric vehicles, which (AT) in India today represents a small eleven large cities. There is also comprise multiple sintered parts. market, but has potential for growth. a growing consumer market for Other major PM part manufacturers The high cost, lower fuel efficiency and electric two- and three-wheelers, are also investing in R&D to introduce India’s poor road conditions, are just as well as light commercial new lines of PM components for EVs, some of the reasons why AT vehicles vehicles. such as rare earth magnets. have not gained significant popularity in the country. In 2015, the market share of automatics was reported to be less than 5%. Powder Metallurgy part producers in India However, some auto analysts believe this will change, and that ATs Mid-sizedOther PM PM could even reach a market share of companiescompanies 40% in the next four years. Reinforcing (27%) (27%) this potential, Hyundai Motors recently reported a significant increase in sales of its automatic transmission vehicles, GKN Sinter Metals + Imports stating that ATs now account for 10% Imports TVS Sundaram of its total sales, compared to just 4% GKN Sinter Metals (7%) (7%) Fasteners in 2015. (60%+ TVS) Sundaram Many components in automatic Fasteners Small transmissions, such as fluid couplings, (60%) businessesOther are currently being imported into the (6%) (6%) country, but Indian PM part manufacturers believe this could easily change. The growing popularity of automatic vehicles could lead to new product Fig. 13 The production of PM components in India is dominated by GKN lines being manufactured by PM Sinter Metals and TVS Sundaram Fasteners (Courtesy Powder Metallurgy companies in the country. Association of India)GKN Sinter Metals + TVS Sundaram Fasteners Other PM companies Imports Other

market. The small business sector (including bush manufacturers) accounts for around 6% of the market (Fig. 13).

Federal Mogul Now part of Tenneco, Federal Mogul entered India’s PM market with the acquisition of the Brico + Goetze India joint venture. The company manufactures sintered components from its facility in Bhiwadi, Rajasthan, and has the capacity to manufacture 12 million valve seats and 13 million valve guides.

GKN Sinter Metals GKN Sinter Metals is the single largest PM part manufacturer in Fig. 14 Plate, gear shift cam (Star Index) manufactured by GKN Sinter Metal, the country. The company originally used in transmission gears (Courtesy GKN Sinter Metal) entered India through a joint venture with Mahindra Sintered Products, a company it later acquired in 2002. GKN Sinter Metals has two Major PM part producers in Mogul, Hitachi Chemical, Motherson manufacturing plants in India, one Sintermetal, Nippon Piston Ring, near Pune and another in Ahmed- India Porite, Pricol, Singhal Sintered, nagar. The company manufactures The two largest PM part manufac- Sintercom India, Speciality Sintered sintered parts for engine, transmis- turers in India are GKN Sinter Metals Products, Star Sintered and Tenneco. sion, shock absorber, G-Rotors, VVT and TVS Sundaram Fasteners, which These companies account for about & VCT Parts. Its total production together account for an estimated 27% of the market. Imported PM capacity is estimated to be about 60% of the market. Other major parts (mainly from Japan and the 12,000 tonnes per year. manufacturers include Federal USA) account for another 7% of the Recent changes in GKN management policy are reported to have seen a rationalisation of its product portfolio. This is said to have created a number of opportunities for other PM part makers, especially those located in the Pune region.

Hitachi Chemical Hitachi Chemical began its operations in India in 2011, with a capital investment of USD 17 million, and has been expanding its facilities at regular intervals ever since. The company caters predominantly to Japanese vehicle manufacturers in India. It manufactures structural parts such as gears and bearing caps, as well as valve guides.

Motherson Sintermetal As part of the US $10.5 billion Samvardhana Motherson Group, Fig. 15 Camshaft left hand gear manufactured by Sintercom India (Courtesy Motherson Sintermetal was formed Sintercom India ) when it acquired Sintermetal in

Spain, in 2012. Since then, it has established a greenfield manufacturing facility in Puducherry to manufacture parts for suspension and powertrain applications. The plant was set up with a production capacity of 5000 tonnes per year, and the company primarily caters to export markets in Europe.

Nippon Piston Ring Japan’s Nippon Piston Ring has a PM manufacturing facility near Bangalore. Components produced here are thought to include valve seats, although exactly what else is manufactured, and at what quantity, is unknown.

Porite Group Fig. 16 Exhaust side gear manufactured by Sintercom India (Courtesy Porite entered India in 2015 and Sintercom India ) earmarked a significant investment of US $28.6 million for its expansion in the country. Since then, the company has been growing at a steady rate, investing in plant and machinery, and is expected to become a dominant player in the Indian PM market.

Pricol Pricol’s PM sales account for around 5% of its total turnover. The company’s PM manufacturing facility is in Coimbatore, where it manufactures PM gears, hubs, G-rotors, valve plates, oilless bearings, gear shifter parts, pistons Fig. 17 Bearing caps are manufactured by Sintercom India (Courtesy and slack adjuster pads. The Sintercom India ) company reported a production capacity of 1000 tonnes per year for its PM plant. Of this, 50% is utilised for the production of components Sintercom India 400 N/M for both petrol and diesel for its pumps division. Over 20% of Sintercom India is a joint venture vehicles. It also manufactures stain- the company’s PM production is for with Austria’s Miba AG. The less steel sintered parts for use in export markets. company began commercial exhaust manifolds. The company’s production in June 2009 and is manufacturing plant near Pune has a Singhal Sintered today publicly traded on the Indian reported production capacity of 3600 Operations began in 2007 with the stock exchange. Sintercom’s engine tonnes per year, which it will increase establishment of a PM manu- product portfolio includes engine to 4980 tonnes per year by FY 2021. facturing plant near New Delhi. drive gears, chain sprockets, belt Less than 5% of the company’s Singhal Sintered manufactures PM pulleys, cam to cam gears and revenue comes from export markets. components for the automotive engine shaft bearing caps for and non-automotive industries. engines ranging from 800 cc to Speciality Sintered Products The automotive industry accounts 2000 cc. Founded in 2001, Speciality Sintered for 50% of produced parts. The Sintercom manufactures a Products has shown remarkable company has a reported capacity of broad range of components for growth in the last five years. The 900 tonnes per year for PM parts. transmission hubs from 60 N/M to company has two manufacturing

facilities near Pune and a third large aftermarket sectors in India as well In addition to these companies, facility is being planned. It has an as globally, reporting around 30% there are PM part manufacturers who in-house design centre and tool exports. exclusively manufacture parts for the room. PM parts are manufactured out non-automotive sector. These include Speciality Sintered Products of three plants located in Hosur, sintered bearings, bronze filters and reported a production capacity of Madurai, and Uttarkhand, with total PM bushes. There are over twenty 8,000 tonnes per year and is in production capacity estimated to be small companies that compete in this the process of expanding this to around 10,000 tonnes per year. The segment. 10,000 tonnes per year. Around 40% company’s iron powder (pre-alloyed The Indian diamond tool industry of its revenue comes from export and pure iron) plant near is also thriving. Major suppliers of markets. Hyderabad is under expansion, and diamond tools for cutting stone include is expected to have a production StaySharp, Optima, SD Tools and Diabu, Star Sintered capacity of 15,000 tonnes per year. who own about 50% of the market. The Founded in 1992, Star Sintered has concrete cutting sector is dominated by two PM manufacturing facilities players like Hilti and Wendt. near New Delhi, with a reported India’s non-automotive PM The Indian tungsten carbide market production capacity of 2000 tonnes component market is amongst the largest in Asia, right per year. Around 20% of the up there with South Korea and China. company’s revenue comes from auto A total of 8% of PM parts manufac- The highest users of Tungsten Carbide components, with the rest coming tured in India are reported to be for in the country are manufacturers of largely from the white goods sector. consumer goods (household appli- cutting tools, wear parts (die inserts) ances, air conditioners, etc). and mining tools. Automobile compa- Tenneco India Many PM part manufacturers nies are the largest users of cutting Tenneco India has one PM part catering to the auto industry also tools (60% market share), followed by manufacturing plant in the country, have a small presence in the non- aerospace, oil & gas, power genera- from which it manufactures shock automotive PM component industry. tion and general engineering compa- absorber parts. As mentioned, around 10% of TVS nies. Aerospace is the fastest growing Sundaram Fasteners’ revenues, segment of users due to the increased TVS Sundaram Fasteners and some 20% of GKN Sinter number of aerospace part manu- TVS Sundaram Fasteners is a Metals’ production come from non- facturers setting up facilities in the powder to parts vertically integrated automotive PM components. Star country. Major manufacturers of cutting manufacturer. The company’s PM Sintered is largely focused on the tools include Kennametal, SECO Tools, division accounts for about 9% of non-automotive sector, with 80% Iscar and Sandvik Coromant, which the company’s total revenue. The of their production catering to this is the market leader with about 15% company caters to both the OEM and market. market share.

Fig. 18 Sandvik Coromant works closely with its customers in India to provide a wide range of solutions (Courtesy Sandvik Coromant)

Additive Manufacturing in India

Aerospace The Additive Manufacturing industry in India is still in its nascent stages. However, the industry expects to see significant growth within the next five years, driven mainly by the country’s aerospace industry. Most aerospace companies report using AM in the alpha stage (pre-production). However, there have been some high profile case studies of AM parts being used successfully by the Indian aeronautics and space agencies. Hindustan Aeronautics Limited has used additively manufactured components in the Hindustan Turbofan Engine-25 (HTFE25).37. It has also used AM to develop a Fig. 19 High pressure compressor stator, manufactured by Wipro 3D in fuel system elbow for the Su-MKI Ti6Al4V, is used to convert kinetic energy into static pressure through aircraft, now certified and in prepa- diffusion and redirects the flow direction of fuel (Courtesy Wipro 3D) ration to begin serial production of the part. The Indian Space Research Organisation (ISRO) used Additive Manufacturing to produce a compo- concepts). A few auto part manufac- model where they additively nent of its satellite communication turers that have invested in metal manufacture a component systems. AM systems include Bajaj Auto, Hero based on a design provided by Motors, Wabtech and Honeywell. a customer. They may optimise Medical/dental the design for the AM process, AM parts for medical/dental appli- Installed systems but rarely make further design cations are another fast growing There are an estimated fifty metal changes. A few companies, like segment and here, in addition to AM systems installed in the country, Wipro 3D and Intech DMLS, are the prototyping and pre-production with EOS taking the lion’s share able to offer value engineering stage, AM is being used for the of the market at 65%, followed by services – developing, testing and manufacture of patient-specific Renishaw at about 18–20%. Other building a prototype or component implants. A case has also been players include SLM Solutions and for specific applications. established for the Additive Manu- the GE-owned Concept Laser. New facturing of titanium implants, as entrants in the market include Materials the cost of imported implants is Desktop Metal and The ExOne group. Around 5 tons of AM powders high. IIT Mumbai, CECRI and CSIO were imported into the country are a few organisations currently Service providers in FY 2019, representing a 5% involved in the production of patient- A large percentage of Indian AM part increase from the previous year. specific implants. producers are service providers such Most AM part manufacturers as Wipro 3D, Objectify, Intech DMLS, and solution providers work with Automotive 3dpd, Rapid DMLS, Think3D, IGTR- a range of materials including The Indian automobile industry also Aurangabad, CTTC-Bhuwaneshwar, aluminium (AlSi10Mg), titanium has the potential to drive growth of Nashik Engineering Cluster and alloys (Ti64, TI64 ELI & TiCP), AM, especially with the recent local- BharatForge. In addition to these, nickel alloys (Inconel 718, 625, isation requirement by the govern- there are government run research HX), SS alloys ( 17-4 PH, PH1, ment for electric vehicles (40–50%, labs that also fall in this category. 316L), maraging steels (300grade), depending on vehicle type). For the These companies differ vastly in their and cobalt chrome (MP1-F75, moment, however, AM is being used abilities and the value they provide. SP2- CE certified dental alloy free primarily for prototyping (proof of Most work on a pure outsourcing of Ni, Be & Cd).

MIM parts manufacturers in India

The MIM manufacturers in India cater largely to export markets, with about 95% of MIM parts manufactured destined for global markets. The small domestic market is mainly in the defence, automotive & textile industries, with a smaller contribution from medical devices. Fig. 20 Stopper slide, manufactured by Indo-MIM, acts as a slide stopper Indo-MIM is the largest MIM in 9 mm pistols. This part won the Best MIM Product Award at APMA 2019. manufacturer in the world and Material used: Hardened and tempered steel MIM 430 (Courtesy APMA) dominates the Indian market, producing 98% of all MIM components in the country. The company Indo-MIM shipped an estimated ment form a small portion of the has two manufacturing plants in 400 million parts in FY 2019, and company’s revenues but are the India and one in the United States. around 92% of parts produced at are fastest growing. Indo-MIM’s in-house tool room exported to the US, Europe and the Other MIM manufacturers can produce over sixty moulds per Far East. include Bangalore MIM Compo- month, with each tool producing Automobile and fire arms parts nents, JJ Orthodontics, Meetu- between one to thirty-two parts constitute 67% of the company’s Raj industries, VDR Metals per one shot. The company has revenues. Another major chunk is and Inmet Technology (a new been growing at 30% CAGR for the generated by parts for consumer division of the mammoth Bharat last five years. products. Parts for medical equip- Forge).

Traditional press & sinter PM India’s metal powder Höganäs India remains the largest parts have had a negligible pres- producers source of Fe metal powders in the ence in the Indian defence and country and accounts for about 65% aerospace industries so far. The India has a number of mid-sized metal of the market. The company has a three large manufacturers of small powder production facilities. In 2018, plant in Ahmednagar that caters to arms in the country have begun an estimated 44,900 tons of metal domestic markets and has a produc- using metal injection moulded powder was produced in India for PM tion capacity of 35,000 tonnes per parts, and the aerospace industry applications (Table 3). Of this, iron- year. The company manufactures has begun experimenting with based powders account for 80% of both pure iron powders and premixed additively manufactured compo- total powder production in the country. alloys. Around 70% of powders sold nents. The overall size of the Whilst iron-based powders are used by the company are to automotive component market in India for primarily in the automobile sector component manufacturers. It imports these two sectors is estimated by (80%), copper based powders are used about 15% of the metal powders it McKinsey at USD $8 billion and $11 in appliances (60%), friction elements sells in India from its sister compa- billion respectively. (18%) and diamond tools (15%). nies across the world.

Estimated tonnage of metal powder shipments for all PM applications in India

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

Iron-base 26,500 31,200 35,400 37,000 30,000 37,000 30,500 30,000 32,050 36,000 Copper-base 12,500 13,700 14,500 14,500 13,700 12,100 10,000 6,000 7,250 8,900 Total 39,000 44,900 49,900 51,500 43,700 49,100 40,500 36,000 39,300 44,900

Table 3 Powder Production in India (Source: Powder Metallurgy Association of India)

With growth slowing down in Outlook for the Indian PM with fluctuating demand and new the European PM markets and community emission standards, but according to plateauing in the North American McKinsey, India’s consuming class markets, metal powder manufac- The uncertainty in domestic demand is expected to expand to 89 million turers are looking to Asia to fuel from the automotive sector has had households by 2024. The pace of their growth. While China remains a mixed impact on the country’s PM infrastructure development is also their largest market at present, part manufacturers. Around 75% encouraging, with an average of India has been identified as a growth are expecting increased production 40 km of road added per day. market, and many large powder in the quarter April–June 2019, and As OEMs demand more R&D manufacturers are looking to either expect to see continued growth in the investment from automotive parts establish manufacturing facilities or following quarter as well. They did not manufacturers, there can be expand their existing footprint in the face any shrinking in their margins inconsistency in component volumes. country. and do not expect to in the near term. Although overall auto production Rio Tinto and Pometon have a The remaining 25% of PM part volumes in India are expected to significant presence in India. They manufacturers who reported reduc- remain the same, variants and do not manufacture powders in the tions in production volumes typi- new platforms are increasing. country, but do have a large sales cally have product portfolios that are In some cases, this can lead to presence. TVS Sundaram Fasteners heavily skewed towards diesel engine unprofitable PM applications. To manufactures powders that it uses components, and export contributions retain margins, a number of larger largely for its own production. The of less than 10%. These companies, PM part manufacturers are moving company manufactures water atom- however, are all investing in plant to more complex and higher density ised iron and pre-alloyed powders of and machinery in the coming quarter parts. This transition may open up a wide density range. (July –September 2019) that will help opportunities for smaller PM firms Smaller Fe-based powder manu- them alter their product mix and open to form partnerships with larger facturers account for about 15% new markets. The after-market will players to supply the lower volume of the market. SLM and Innomet continue to offer a steady revenue components required by OEMs. Powders are two such companies. stream for diesel engine components, SLM manufactures sponge iron and but it is insufficient to sustain the atomised iron powders. Innomet larger PM companies. Author specialises in manufacturing Many PM parts manufacturers Kadambari Gopinath customised grades of metal alloy believe that the speed of recovery of Fluidtherm Technology powders containing iron, copper, tin, the automobile segment is dependent SP 132 III Main Road, zinc and cobalt. on the fallout from the coming Ambattur Industrial Estate Other major manufacturers of government elections and any subse- Chennai 600 058, copper powders in India include quent changes to interest rates in the India PP Patel and Sarda Industrial country. Predictions of growth of the [email protected] Enterprises. GKN Sinter Metals domestic PM market in the next full manufactures copper powder for year have been conservative. Almost its own consumption out of its plant all PM part manufacturers believe Sources of data in Ahmednagar (80–100 tonnes that growth will be between 4–6% in per year). the coming year. Many companies [1] Automobile industry figures, plan to supplement domestic growth including growth, production, exports MIM and AM powders by trying to increase their share of etc., from the Society of Indian Indo-MIM commissioned a powder exports. Some 40% of Indian PM part Automobile Manufacturers (www. manufacturing unit in 2017, where manufacturers expect exports to grow siamindia.com) it manufactures MIM powders moderately by 5–10%, while another [2] Investment data, including infra- primarily for its own consumption. 10% expect it will grow even faster. structure data etc., from India Brand Its atomisation facility consists The overall sentiment seems Equity Foundation (www.ibef.org) of vacuum induction melting with to be positive and almost all PM [3] Media articles referred to and inert gas atomisation. The company part manufacturers are making quoted include Economic Times recently began manufacturing AM investments in plant and machinery in (www.economictimes.com) and powders in stainless steel, Co-Cr the coming quarter (July–September Financial Express (www.financialex- and Inconel grades. 2019). Even with the recent drop in press.com) Midhani, a government owned growth rate for the automobile sector, [4] Trends, outlook and industry manufacturer of superalloys, plans there is a great deal of optimism in information from conversations with to begin manufacturing titanium and the Indian automotive industry. The industry leaders nickel superalloy materials through next six months are expected to be [5] Powder Metallurgy Association of gas atomisation in 2020. tough on the industry, as it battles India (www.pmai.in)

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Award winning automotive applications showcase potential of PM

There are many applications in the automotive sector where the use of Powder Metallurgy offers numerous advantages over other metal working processes. From reduced manufacturing costs to improved properties and unique material characteristics, Powder Metallurgy can be used to produce a wide range of automotive components. Over recent years, many of these parts have been the recipient of industry awards, and in this article, Dr David Whittaker highlights a number of the winning parts to showcase the potential for PM in the automotive sector.

PM technology’s strength lies in nant driver for the continued growth motive PM applications are widely the manufacture of geometri- of PM applications. spread around the vehicle, but, as cally complex components in high Globally, the proportion of seen in Fig. 1, engine and transmis- production volumes. As the automo- Powder Metallurgy components sion components have emerged tive industry is the leading consumer destined for automotive applications as dominant sources of demand. of a wide range of such components, is generally understood to be around The actual quantity and total it is unsurprising that this sector 80% of total press and sinter PM weight of PM components found has historically emerged as a domi- production. The established auto- in each vehicle does, however,

Typical applications for Powder Metallurgy components

Shock absorber Camshaft Valve components Clutch components Fuel system VVT systems Engine valves assembly lobes guides hub pumps cam lobes connecting rods pistons bearing caps seat inserts backing plate gears sprockets armatures rod guides pulleys gerotors rotor heat sinks sprockets sprockets lever arms lock plates Power steering Transmission rocker arm pump rotor Turbocharger sensor rings spark plugs drive pulley gears end caps sprockets yoke vanes bearings pulleys cam rings bearings differential gear stator rings hubs thrust plate stators Door/roof bushings sensor rings one-way clutch hinges sun gear bushings Synchroniser Parking sprockets housing gear thrust washers hub Braking system sensor rings disc brake pads Crankshaft Steering column ABS sensor rings HVAC bearing caps Oil pumps Planetary carrier drive pulley Water pump friction materials bearings pulley gears frame cams flange bushings plates sensor gerotors gears gears impellers pistons hubs sprockets sprockets spacers bushings pulley

Fig. 1 A selection of automotive components that can be produced by PM

Fig. 2 Powder Forged connecting rods, such as this one produced by Metaldyne (now AAM), demonstrate the use of powder metal technology in critical and demanding applications

vary considerably depending on auto with Europe slightly lower at 8 kg. Award winning parts manufacturer and world region. Typi- It should be noted that vehicles in cally, in North America around 13 kg North America do tend to be larger The Powder Metallurgy industry’s of PM parts are found in the average than those models found in Europe trade associations play an important sedan, rising to 20 kg in a mid-range or Asia, but it is clear that there is role in promoting the use and further crossover and around 34 kg in a large still potential to expand the market adoption of PM technology. From cost SUV. In Asia the figure is estimated for PM in many world regions. savings and environmental impact, to be near 9 kg for the average car, to novel applications and unique properties, the Powder Metallurgy process has much to offer the industries of today as well as the technologies of tomorrow. The automotive industry is one such industry and is certainly not overlooked when it comes to recogni- tion through industry awards. Many of the trade associations, such as the Metal Powder Industries Federation (MPIF), Japan Powder Metallurgy Association (JPMA) and European Powder Metallurgy Association (EPMA), regularly include automotive components in their award presentations. This article provides a review of award-winning PM structural part applications as presented in recent years by regional trade associations. Many of the awards demonstrate the continuing dominance of PM Fig. 3 Duplex cam sprocket manufactured by NetShape Technologies engine and transmission components (Courtesy MPIF) for internal combustion engines.

However, it should be recognised that the trend towards vehicle drive electrification may affect this balance in the medium term and, therefore, some commentary is provided on potential PM functional part applications in electric vehicles, driven by this development trend and highlighted in a recent seminar organised by the EPMA.

Automotive engine parts

Over the years, many automotive engine components have been recognised for their use of Powder Metallurgy in meeting the increasing demands of the automotive industry. Components such as the Powder Forged connecting rod, shown in Fig. 2, have been pivotal in the acceptance of powder metal parts in critical applications. Recent engine part awards have included PM sprockets and valve seats, as well as Fig. 4 Cloyes Gear & Products, Inc. produced these rubberised engine main bearing cap components. sprockets for use in General Motors’ Generation II V-6 Engine (Courtesy MPIF)

Sprockets A 2017 MPIF Award of Distinction was presented to NetShape Tech- nologies, Floyds Knobs, Indiana, USA, for a copper steel duplex cam sprocket made for US Tsubaki Automotive, LLC (Fig. 3). This part goes into the 4.4 litre Big Lion diesel engine in Land Rover’s flagship vehicle. An original PM design, the part offers an estimated 30% savings over the cost of machining it from wrought material. In 2016 the MPIF made an Award of Distinction to Cloyes Gear & Products, Inc., Division of HHI/MPG, Subiaco, Arkansas, USA, for three PM steel sprockets made for Iwis Engine Systems LP (Fig. 4). The components, a rubberised crankshaft sprocket and two rubberised oil pump sprockets, are used in a General Motors Generation II High-Feature V-6 Engine, currently installed in the Cadillac CT6 and ATS, GMC Acadia and Chevrolet Camaro. The patented rubber design used on the crankshaft sprocket provides Fig. 5 Hitachi Chemicals Co. Ltd use die wall lubrication in the compaction improved noise, vibration and harsh- stage to achieve high density (Courtesy JPMA)

Fig. 6 A matrix toughened material, developed by Fine Fig. 7 These valve seats from Fine Sinter Co. Ltd offer Sinter Co. Ltd and Toyota Motor Corporation, is used in cost savings by minimising the amount of wear resistant these valve seats (Courtesy JPMA) material used (Courtesy JPMA)

ness characteristics that exceed the ties of 7.5 g/cm3 and higher shape compacting method in which coating engine manufacturer’s demands. complexity, whilst eliminating the of the lubricant is completed in the Fabrication via PM provides an compacting speed rate-determining die operation cycle from ejection estimated 30% saving over parts step in the die lubricant coating after the compacting process to machined from steel bar or forgings. process. In lubricant coating using return for filling, thereby achieving The JPMA presented an award the conventional spray method, the same compacting speed as in to Hitachi Chemicals Co. Ltd in 2015 reduction of compacting speed and conventional compacting. In addi- for a high density PM steel sprocket the ability to respond to the incor- tion, in the spray method, the die is (Fig. 5) which was produced using poration of lightening holes were generally heated for the purposes of die wall lubrication in compaction. significant challenges. To solve increasing the adhesion between the The developed technology provides these problems, Hitachi Chemicals die wall surface and a solid lubricant, products with sintered densi- developed a new die wall lubrication or drying the solution of a solid-liquid mixed lubricant. The newly developed method makes it possible to obtain the desired high-density product properties in PM sprockets without heating the die, and has resulted in higher productivity in comparison with the tooth flank form rolling method and the conventional warm die wall lubrication compacting method.

Valve seats In 2016 and 2015, the JPMA made awards for two valve seat applications that were both enabled by novel material developments. Fine Sinter Co. Ltd and Toyota Motor Corporation received a prize for the development of a valve seat material (Fig. 6) with improved anti-adhesive wear properties by distributing fine hard particles in the matrix. Valve seats for auto- Fig. 8 Main bearing caps, made by GKN Powder Metallurgy, are used in the mobile engines are required to have turbocharged four-cylinder engine in the Alfa Romeo Giulia (Courtesy MPIF) high anti-wear properties and hard

particles are added and distributed in the matrix to obtain a ‘cobblestone effect’ to achieve this requirement. Additionally, the combustion heat from engine operation produces oxides, whose major components are Fe, on the surface of the valve seat. These oxides also improve the anti-adhesive wear with the valve and they create a synergetic effect with the conventional hard particles in the matrix material. However, recent improvements in engine efficiency have created more difficult conditions for Fe oxide formation, and other means are needed to strengthen the valve seat against adhesive wear. One option is to increase hard particle content. However, this option could cause degradations in compacta- bility, machinability and machined surface roughness of the valve seat material. The development by Fine Fig. 9 AAM Powertrain manufactures this sprocket for a VVT sub-system in Sinter uses hard particles with an GM’s three and four cylinder engines (Courtesy MPIF) increased austenite diffusion phase compared to conventional materials. These hard particles improve adhe- It was also found that the use of Powder Metallurgy parts sive properties with the matrix, solve highly wear resistant material as the used in engine ancillary the concerns over surface roughness seat material reduces heat conduc- sub-systems after machining by detachment of tivity because of the hard layer, hard particles, and provide a 35% cost which includes carbide. Therefore, reduction compared with the conven- decreasing the proportion of highly Recent developments in this tional material. wear resistant material in the valve category have been dominated A year earlier, Fine Sinter Co. seat improves total heat conductivity by applications in Variable Valve Ltd received an award for a modi- and provides a heat reduction effect – Timing (VVT) and Variable Cam fied design concept for valve seats an essential requirement in modern Timing (VCT) sub-systems, with (Fig. 7). This valve seat provided an higher efficiency engines which components for turbochargers also improvement in cost effectiveness operate at higher temperatures. featuring. by minimising the amount of highly wear resistant material used through Main bearing caps VVT sprocket the reviewing of the layer boundary In 2018, an MPIF Grand Prize was In 2018, an MPIF Award of Distinc- angle. The valve seat has expensive, presented to GKN Powder Metallurgy tion went to AAM Powertrain, highly wear-resistant material (seat for a copper steel PM main bearing Detroit, Michigan, USA, for a material) on the seat surface where cap made for FCA US LLC (Fig. 8). The pre-alloyed steel VVT sprocket the valve impacts, because impacting part is used in the 2.0 l all-aluminium (Fig. 9), which is used in overhead the valve wears the seat. Therefore, turbocharged four-cylinder engine in camshaft GM inline three- and in order to improve cost effective- the Alfa Romeo Giulia. four-cylinder engines in cars such ness, the developed valve seat has Although PM main bearing caps as the Buick Encore and Envi- two layers with a cheaper material have dominated engine design for sion and the Chevrolet Cruze and (base material) on the cylinder head more than two decades, the design of Malibu, among others. side because wear resistance is not this part is said to break new ground. The six pitch inverted tooth was required on this part of the compo- Requirements for engine weight specifically selected to address nent. This development improved the reduction drove the designers to an concerns with NVH (noise, vibra- layer boundary angle to 45°, which is ‘upside down’ sculpted version. This tion and harshness) as well as parallel to the valve-impacting surface novel design delivers a part that is with durability and rotating mass. angle. The amount of expensive said to be around 23% lighter than The part demands very consistent material in the valve seat is therefore previous versions and offers 10% powder filling to achieve the reduced. better fatigue strength. extremely tight tolerances required.

succeeded in building a consistent higher productivity line. This line can prevent the risk of cracks and chips, due to offline handling, by in-lining the green machining equipment, linking it with the compaction process, and machining with a touchless and stockless concept. In addition, traceability has been enhanced by attaching a two-dimensional barcode by laser beam to each product before sintering, enabling the tracing of product quality and manufacturing information, and the risk of cracks and chips in green machining has been decreased.

VVT control plate Sumitomo Electric Industries Ltd Fig. 10 Complex pulley with high-accuracy non-circular gear teeth for a VCT received a further JPMA prize in sub-system manufactured by Sumitomo Electric Industries (Courtesy JPMA) 2016 for the development of a laser quenched multistage, complicated shape side plate, adapted to the VCT pulley award for a component, this prize is high torque phase control system In 2017, Sumitomo Electric Indus- of interest as it highlights some of of a VVT rotor (Fig. 12). High torque tries Ltd. received a JPMA prize the unique manufacturing capabili- was necessary for the control- for a pulley with non-circular – in ties of PM. The set-up provides the ling phase of the rotor and, in this case, triangular – gear teeth, simultaneous green machining of the conventional model, several which is a part of a VCT system in holes and grooves, and the attach- springs were attached to the rotor a 3-cylinder engine (Fig. 10). The ment of a two-dimensional barcode itself to control phase. However, part was developed to achieve a to ensure high quality. Also, the in the developed model, a system reduction in vibration. To deliver the line provides successful touch- which controls phase from outside required improvements in function, less manufacturing of parts, from the unit was adopted. Therefore, high dimensional accuracy, espe- compacting to sizing. a large spring, which slides with cially to the extremely tight geomet- VVT systems control the timing the side plate, was attached and rical tolerances of the non-circular of valve opening and closing by the previously used aluminium external teeth (the outer diameter, changing the phase of the rotor casting could be replaced with the whole circumference, profile and with oil pressure, enhancing a sintered iron part. Regarding squareness), was needed. Uneven power output and reducing fuel the product shape, the side plate density after compaction and defor- consumption. VVT parts are rapidly was difficult to compact, due to mation due to sintering were identi- developing, with, for example, the the many tangs required to fix the fied as factors affecting external rotor becoming unified with oil spring to the surface and the deep tooth accuracy. These were resolved control valve, and the demand for oil groove on the opposite surface. by optimising the sizing conditions. holes and grooves, which cannot In order to maximise the benefits In relation to the shape require- be moulded in compaction, has of using PM, multistage compac- ments for subsequent assembly, increased. Therefore, the increase tion was successfully designed in the female screw holes and four oil in machining cost, including at an early stage. Furthermore, passing slots had to be formed using deburring after sintering, has the side surface of each tang side cores in compacting. become a problem area. demanded good wear resistance, To solve this problem, Sumi- due to the sliding of the spring. VVT rotors tomo Electric has applied green Although the surface was uneven, Sumitomo Electric Industries Ltd. machining, enabling rapid laser quenching could be applied had earlier been awarded a JPMA machining without burr formation, to achieve the required hardness Process Development Prize, in 2016, and has sought to decrease cost. without decreasing accuracy by for a manufacturing line used to The company developed a multi- using a simple jig and program, produce Variable Valve Timing (VVT) machining technology for holes instead of induction hardening with parts (Fig. 11). Although not an and grooves in one operation and a complicated coil design.

Fig. 11 Sumitomo Electric Industries Ltd’s VVT parts manufacturing-line allows the simultaneous green machining of holes and grooves (Courtesy JPMA)

Turbocharger valve bushings Finally in this application category, Hitachi Chemical Co. Ltd. received a JPMA award in 2015 for the development of an austenitic sintered material with excellent heat and wear resistance and for use in the valve bushing in a turbocharger (Fig. 13). Turbochargers have conventionally been used in diesel engine vehicles, but their usage has now also been expanding into gasoline engines. Since the exhaust gas temperatures in gasoline engines are higher than those in diesel engines, austen- Fig. 12 This complex side plate is manufactured by Sumitomo Electric itic materials tend to be used as Industries for a high torque control system of a VVT rotor (Courtesy JPMA) turbocharger parts because of their superior heat resistance. To respond to these requirements, a new austenitic sintered material with higher wear resistance has been developed. The technical success of this material was said to depend on dispersion of carbides in the matrix, introduced to improve wear resistance. Increasing the amount of carbide through an increase in the carbon content does improve wear resistance but also leads to the deterioration of oxidation resistance because of the lower Cr content in the matrix. However, it was found that using finer carbide could improve wear resistance without decreasing oxidation resistance. The developed material has proved to be successful in penetrating the market for turbocharger bushings for gaso- Fig. 13 Hitachi Chemical Co produced these valve bushings for turbochargers line engines. (Courtesy JPMA)

Transmission component applications

Planetary carriers Recent new PM applications in automotive transmissions have been dominated by planetary carriers. In 2018, the MPIF Grand Prize was awarded to GKN Powder Metallurgy for an aluminium PM planetary reaction carrier, which it produces for General Motors (Fig. 14). The carrier goes into the all-new GM 9T50 nine-speed transmission, offered in such vehicles as the Chevrolet Malibu and the Equinox crossover. Made from a unique metal matrix composite (MMC) aluminium alloy system and mated to an overdrive carrier, this first-of-its-kind two-piece design required extremely tight tolerances. Also in 2018, MPIF made an Award of Distinction to Stackpole International, Canada, for a PM Fig. 14 GKN Powder Metallurgy manufactures this aluminium planetary copper-steel rear planetary carrier reaction carrier for GM’s 9T50 nine-speed transmission (Courtesy MPIF) (Fig. 15). The component is used in a new ten-speed automotive transmission, developed jointly by Ford and General Motors and found in such vehicles as the Ford Mustang and GM Camaro. The assembly consists of a clutch hub and a spider, which are joined using a novel sinter- brazing concept. The creative design of the ferrous carrier enabled it to win out over an aluminium casting design by delivering lighter weight and superior strength. In 2017, an MPIF Grand Prize also went to GKN Powder Metal- lurgy for a planetary carrier assembly made for Ford Motor Company (Fig. 16). The sinter- brazed copper-steel assembly, comprising a cage and a flanged hub, goes into the all-new ten- speed transmission for the Ford F-150 pickup. The finished carrier assembly requires only simple milling and turning operations to hold the tight tolerances on the bearing bores, pinion pin shaft Fig. 15 Rear planetary carrier made by Stackpole International (Courtesy MPIF) holes and thrust faces.

Fig. 16 This planetary carrier assembly, produced by GKN Fig. 17 Stackpole International make this sinter brazed Powder Metallurgy, is used in Ford’s F-150 ten-speed planetary carrier for ZF’s nine-speed automotive transmission (Courtesy MPIF) transmission (Courtesy MPIF)

In the same year, the MPIF also of the legs, green machining was process. After brazing, the steel presented an Award of Distinction to adopted to provide further cost hub was welded to the sleeve. For Stackpole International for a sinter- benefits. the purpose of cost reduction, a brazed planetary carrier made for In this application the two PM completely automatic production ZF, Germany (Fig. 17). The assembly, carriers A, B (each made from line from compaction to machining consisting of a guide plate and a Fe-2Cu -0.9C) and a steel sleeve, was developed and the number of spider, goes into a new nine-speed having an optimal joint design, operators was halved. Productivity automotive transmission. The PM were brazed during the sintering was improved through the introduc- design solution for a lightweight carrier met all the customer’s design and durability requirements. This same application had received an award from the EPMA at the 2016 PM World Congress, Hamburg. The final example of a recent JPMA award for a planetary carrier was made to Toyota Motor Corpo- ration for a ravigneaux planetary carrier developed for a new high- efficiency automatic transmission. It consists of a PM carrier A, a PM carrier B, a steel sleeve and a steel hub (Fig. 18). The carrier design was optimised for PM to provide a significant reduction in manufacturing costs compared with forging and stamping. The stress to be applied to the ravigneaux carrier was reduced to below the fatigue limit by optimising the shape of the part at the points where stress was concentrated. The average density of this PM carrier is 7.05 g/cm3. Fig. 18 Toyota Motor Corporation manufactures this low-cost sintered For forming of the different heights ravigneaux planetary carrier in-house (Courtesy JPMA)

tion of a new filling method to stabi- lise filling density, and tool change- over time was reduced to less than 160 seconds. These developments contributed to substantial improvements in cost competitiveness. It is expected that these technologies will be applied to global production in the future.

Clutch component There have also been a number of recent awards for PM transmission applications other than planetary carriers. In 2017, an MPIF Award of Distinction was given to Burgess- Norton Mfg. Co. Inc., Geneva, Illinois, USA, for a sinter-hardened Fig. 19 Burgess-Norton manufactures this pocket plate for a controllable steel pocket plate made for Means clutch (Courtesy MPIF) Industries Inc. (Fig. 19). The part is a major component of a controllable clutch, a new design for multi- speed transmissions.

Locking differential gear In 2016, a Grand Prize was awarded to GKN Powder Metallurgy for a powder forged electronic locking differential gear set made for Ford Motor Company (Fig. 20). Comprising five components, namely a side gear, two pinion gears, a locking side gear and a locking plate, the gear set is used in the rear axle differential of the Ford F-150 light truck, the first time Fig. 20 Powder Forged electronic locking differential gear set made by GKN forged PM differential gears have Powder Metallurgy for Ford (Courtesy MPIF) been used in such an application. The higher performance delivered by the forged PM differential gears compared to that of competing metal-forming processes will help usher in downsized gear systems, satisfying a critical need in future automotive design.

Thrust washer In 2015, FMS Corporation, Minne- apolis, Minnesota, USA, was awarded a Grand Prize for a thrust washer and two back-up washers made for its customer Allison Transmission (Fig. 21). The components play a critical role in the function of Allison’s new TC10 automatic transmission for Class Fig. 21 FMS Corporation produces this thrust washer and back-up washer for a 8 (18-wheel) tractors. A first of its ten-speed automatic transmission (Courtesy MPIF) kind for the trucking industry, this

ten-speed automatic transmission enables even inexperienced drivers to achieve 5% fuel savings over typical manual transmissions, thus contributing to a significant lowering of CO2 emissions. Fabricated from a proprietary low-alloy PM steel, the three parts are warm compacted to achieve high green density, then vacuum sintered at high temperature, gas-pressure quenched and tempered. They are produced very close to net shape, with only precision machining of some surfaces performed to improve the micro-finish as well as for dimensional accuracy. While these washers were an original PM design, they are estimated to save 30% over the cost of comparable forged/machined components.

Oil pump drive sprocket A 2017 MPIF Award of Distinc- tion was presented to Keystone Powdered Metal Co., St. Marys, Pennsylvania, USA, for an oil pump drive sprocket made of prealloyed steel and fabricated for Linamar Corporation, Canada (Fig. 22). The Fig. 22 Oil pump drive sprocket made of prealloyed steel by Keystone Powdered part is used in a new ten-speed Metal for its customer Ford (Courtesy MPIF) automatic transmission that goes into the Ford F-150 truck. The part passed extensive durability testing with particular emphasis on noise, vibration and harshness requirements, so critical in automatic transmissions.

Drive transmission gear Finally, although not a prize winning component, this fourth drive transmission gear developed by Sweden’s Höganäs AB, was a notable entry in the 2016 EPMA Awards (Fig. 23). With a density of 7.3 g/cm3 and a tensile strength of 990 MPa, this component was designed to exploit and demonstrate the full potential, and enduser benefits, of PM in this application. Together with twelve technical partners and suppliers from the entire PM value chain, a further project resulted in the world’s first optimised six-speed manual transmission designed for PM gear Fig. 23 Fourth-drive transmission gear developed by Höganäs demonstrates technology. the potential for PM in this application (Courtesy Höganäs AB)

Powder Metallurgy in many other automotive systems

There have also been recent developments for new PM applications in other automotive systems.

Car seat component In 2017, an MPIF Grand Prize was given to GKN Powder Metallurgy for a copper-steel output pulley made for Nidec Automotive Motor Americas (Fig. 24). The part goes into an electric reclining Fig. 24 GKN Powder Metallurgy make this output pulley for rear seat reclining mechanism in a minivan rear seat mechanism (Courtesy MPIF) application. The part offers a high level of functionality in the small footprint mechanism and includes the groove for cable retention, the cam for radial movement and stops at both ends.

Steering column The MPIF Grand Prize in 2015 went to Keystone Powdered Metal Company, for a rake cam, right-hand and left-hand guides and an eccentric cam made for its customer Nexteer Automotive (Fig. 25). The diffusion-alloyed steel components are used in Cadillac ATS and CTS, Chevrolet Impala and GM Holden Commo- dore (Australia) steering columns. They are key elements of the column’s tilt and telescope adjustment feature, serving a vital role in maintaining the column’s posi- Fig. 25 Keystone Powdered Metal Company‘s steering column cams and guides tion during a crash event. are used in GM models (Courtesy MPIF) The multi-level parts are fabricated to net shape, with in-line heat treatment and tempering being the only secondary operation preformed to ensure the required hardness and strength. The rake cam and guides have features that allow for a mechanical lock of the plastic over-mould, in an operation performed by Agapé Plastics, Inc. The economic targets of the customer’s preferred design for the steering column tilt/telescope adjustment and lock—with a “pin pocket” that gives a positive detent feel—could Fig. 26 Multiple PM components made by Keystone Powdered Metal Company be met only with the flexibility are used a steering column (Courtesy MPIF) offered by PM.

In 2016, the MPIF Grand Prize was again presented to Keystone Powdered Metal Co., St. Marys, Pennsylvania, USA, this time for a total of seven PM components used in the steering column of the Chev- rolet Colorado and GMC Canyon trucks (Fig. 26). The rake cam, left-hand inner cam, retainer guide, right-hand rake teeth energy-absorbing eccentric strap cam, column mounting insert teeth and left-hand rake teeth are made for Nexteer Auto- motive. The heat-treated diffusion- alloyed steel components are key elements of the steering column’s tilt and telescope adjustment feature, serving a vital role in maintaining the column’s position during a crash event. The rake cam has features that allow for a mechanical lock of the plastic lever, which is over-moulded in an operation performed by Agapé Plastics, Inc. Fig. 27 This award-winning drive pulley is manufactured by Capstan Atlantic Power steering systems for an electronic power steering system (Courtesy MPIF) In 2016, two separate MPIF Awards of Distinction featured drive and driven pulleys for electric power steering systems. The first went to Capstan Atlantic, Wrentham, Massachusetts, USA, for a drive pulley (Fig. 27). The iron-copper part is used in assemblies found in the Ford Focus and Escape vehicle platforms. This unique six-level component requires tight tool-wear control. Powder Metallurgy was chosen as the fabrication method because it offered far better precision than the die-cast alternative at a competitive price. The second award went to GKN Powder Metallurgy for a copper- steel driven pulley for an electric power steering system made for Nexteer Automotive (Fig. 28). The pulley is a complex net-shape- compacted part with a unique helical geometry and tight tolerances. Close collaboration with the customer in the design of the part, which includes net-formed lightening holes, yielded savings of Fig. 28 GKN Powder Metallurgy manufactures this copper-steel driven pulley more than 10%. for an electric power steering system (Courtesy MPIF)

improve the dimensional precision of an as-induction hardened body. By setting the sizing conditions to minimise residual stress, it was possible to reduce the deformation during induction hardening and to achieve the required parallelism, with a dimensional accuracy of 50 µm, without post-processing.

Wiper motor self-lubricating bearings Diamet Corporation won a further award for the development of a PM self-lubricating bearing that is designed to form part of the armature used in an electronically controlled wiper motor, as a typical application example (Fig. 30). In order to improve pressure and wear resistance, the company targeted excellent sliding and lubricating performance with higher hardness Fig. 29 Diamet Corporation make this sprocket drive for a next-generation and strength than conventional automatic transmission oil pump (Courtesy JPMA) Fe-Cu system oil-impregnated sintered bearings. For better sliding characteristics, the developed bearing material incorporated a large amount of copper (exceeding the solubility limit in iron) and had a microstructure with a large fraction of copper phases. In addition, as a result of optimising the raw material particle size of the copper powder and graphite and the sintering conditions, the material developed an Fe-Cu system composite structure, in which undissolved copper phases and free graphite are dispersed and distributed, resulting in high hardness and high strength. Diamet also succeeded in securing the Fig. 30 Bearings produced by Diamet Corporation for an electronically dimensional accuracy of the sizing controlled wiper motor (Courtesy JPMA) process by achieving almost zero (< 0.1%) dimensional change rate in sintering. Sprocket drive for automatic sprocket with 6.8g/cm3 density The developed bearing material transmission oil pump was used for this unit, instead of is said to achieve a wear resist- The JPMA has also made awards a fine-blanked sprocket. Although ance of more than four times that in this category. Firstly, Diamet induction hardening treatment is of a conventional bearing, under Corporation was awarded a prize often used for gear tooth surface the electronically controlled wiper for its development of a sprocket hardening, post-processing motor operating conditions. The drive for a next-generation is required since dimensional company claims that there is no fuel consumption AT oil pump accuracy deteriorates. In order to other example of this type of PM (Fig. 29). From a cost point of achieve both mechanical strength bearing material in the market- view, an Fe-Cu-C based sintered and low cost, Diamet has tried to place.

Electric motor applications In the late 1990s, the EPMA gave an award to Höganäs AB, Sweden, for a new high-purity water atomised iron powder called Somalloy. This powder is chemically treated to provide an electrically insulated inorganic layer on each particle and was aimed at new soft magnetic applications in electric motors. The powder could be compacted to high densities, thereby improving magnetic properties, and, by heat treating, or curing, in air at around 650°C, a bond was developed between the powder and the insulating layer to give the Fig. 31 The YASA P400 electric motor is produced using SMC iron powder component adequate strength. components (Courtesy YASA Motors) PM bonded magnets are simple to produce, are more energy efficient and offer 3D design for new motors. Soft magnetic components have been produced from this type of powder since the late 1990s, including some for applications in hybrid and electric cars. It was the ability to achieve 3D magnetic properties and the net-shape capabilities of the SMC iron powder that prompted YASA Motors in Oxford to choose the SMC Somalloy material for its new compact axial flux e-motors (Fig. 31). Their modular design allowed for stackability – up Fig. 32 YASA motors can be used to power a number of electric vehicles to four motors in parallel, which (Courtesy YASA Motors) can generate a power of 400 kW – and direct drive. YASA stated that this eliminated the need for costly and inefficient transmissions, further reducing overall weight of the vehicle and cutting production and maintenance costs. PMG Fussen, Germany, has also developed SMC-based components for transversal flux electric motors made by Compact Dynamics GmbH (Fig. 33). Toyota and Honda in Japan are already using SMC iron powder cores for power induc- tors, also called reactors or choke coils, for switching power supply in hybrid vehicles. So applications for SMC magnets are growing and there is much potential here for the Fig. 33 SMC components produced for electric applications (Courtesy PMG PM industry. Füssen GmbH)

PM Functional materials to meet the needs of next-gen auto applications

A seminar organised by the EPMA in 2018 discussed a number of Powder Metallurgy processed functional materials with potential applications in next generation electrified vehicles. These included the following topics.

Fig. 34 Influence of rate of compression in calendering of lithium-ion battery High-energy density battery electrodes electrodes and electrolyte The process steps for lithium- ion batteries are mixing and dispersing, coating and drying, calendering and assembly and electrolyte filling. In the calendering process, the influences of the rate of compression have been assessed in relation to a number Use (Tank to wheel) of parameters: the tortuosity Fuel provision (Well to tank) of the pathways through pores, density level and conductivity, Veh. manufacture (Cradle to grave) porosity level and diffusion coef- ficient and discharge capacity (Fig. 34).

Fuel cells

Probably the most reasonable CO2 footprint comparisons for fuel cell usage vs. internal combustion Fig. 35 Lifecycle CO2 emission comparisons, including “cradle to grave” data engines would be the full vehicle ‘cradle to grave’ figures shown in Fig. 35, which include the embedded carbon contents for Laminated vehicle manufacture. Steel-sheets SMC Axial-flux 30 Radial-flux Single sided Magnetic material (soft and hard) SMC Axial-flux applications in electric motors 25 Double sided and ancillary systems 20 The use of SMC components for the design for high power 15 density using axial-flux motors (single sided and double sided) 10 is summarised in Fig. 36. This technology is used in electric 5 traction drives. 0 Ref. RF IPM Basic YASA Transmission gears for electrified transmissions Permanent Magnets Soft Magnets (Lam/SMC) Winding Total There is a wide variety of possible transmission architectures for Fig. 36 Use of SMC components in designing for high power density (kW/kg) hybrid and BEV drives (Fig. 37). It in axial-flux motors is envisaged that ultimately the

Fig. 37 The high variety of possible hybrid and BEV drive architectures

Electrical Actuator Capillary wick 3 Flood Evaporator

Twin Valve

Bypass Compensator

Fig. 38 LHP arrangement for exhaust heat recovery in hybrid vehicles

trend will be towards placing the shortened ICE running times. The References ‘e-machine’ in the P4 position where evaporator is placed in the exhaust it would be de-coupled from the ICE line and the condenser in the coolant Metal Powder Industries Federation and put on the rear wheel axle. In circuit (Fig. 38). The benefits of using www.mpif.org such an architecture, the gearbox LHP technology in this application are would be of significantly simplified fast response times, highly efficient Japan Powder Metallurgy Association design compared with a current, heat transport and the absence of an www.jpma.gr.jp conventional gearbox. electric pump. European Powder Metallurgy Asso- Capillary wick materials for loop ciation heat pipe application in electric Author www.epma.com vehicles Such materials can be used for Dr David Whittaker exhaust heat recovery in hybrid Tel: +44 1902 338498 vehicles for shortened cold starts and [email protected]

© 2019 Inovar Communications Ltd Summer 2019 Powder Metallurgy Review 87 International exhibition and conference on the next generation of manufacturing technologies Frankfurt, Germany, 19 – 22 November 2019 formnext.com

The entire world of additive manufacturing

Design and software

R&D

Metrology

Materials

Post-processing

Services Manufacturing solutions Pre-processing

Additive manufacturing surrounds a whole world of processes. Instead of a world tour you only need one ticket – for Formnext! Where ideas take shape.

International exhibition and conference on the next generation of manufacturing technologies Frankfurt, Germany, 19 – 22 November 2019 Spark Plasma Sintering: formnext.com Method, systems, applications and industrialisation The entire world of additive manufacturing

For around thirty years, Spark Plasma Sintering (SPS) has been of great interest to Design and software the Powder Metallurgy industry and academia alike, for both product manufacturing and advanced material research and development. Today in Japan, a number of components made using SPS are already in production, with the process moving from the R&D stage to practical industrial use. In this article, Dr Masao Tokita, of NJS Co., Ltd., introduces the latest in SPS technology, discusses the development of SPS systems and highlights a number of industrial applications. R&D

Metrology

It is widely recognised that the Spark including those found in Europe, the century [1-3]. Today’s fifth genera- Plasma Sintering (SPS) method is USA, Russia, China, Korea and others. tion SPS systems are capable of Materials an advanced processing technology, SPS technology is seen as a producing parts of increasing size, used to produce a homogeneous, promising technology for innovative offering improved functionality, highly-dense, nanostructural processing in the field of advanced reproducibility, productivity and cost sintered compact, as well as in new materials fabrication in the 21st effectiveness. Post-processing Functionally Graded Materials (FGMs), fine ceramics, composite materials, wear-resistant materials, Services thermo-electric semiconductors and Manufacturing solutions biomaterials. Originating in Japan, the technology, also referred to as a Pre-processing pressure-assisted pulse energising process, Field-Assisted Sintering Technology (FAST), Electric Current Activated/assisted Sintering (ECAS) or Pulsed Electric Current Sintering (PECS), is today finding new applications in many global regions. Additive manufacturing surrounds a whole world of processes. As of January 2019, over five Instead of a world tour you only need one ticket – for Formnext! hundred SPS systems are installed in Japan alone, located in universi- Where ideas take shape. ties, technical colleges, national institutes and private companies for use in both the R&D and manufacturing sectors. It is estimated that around one thousand SPS systems Fig. 1 Spark Plasma Sintering (SPS) can be used to produce a variety of are currently installed globally, components, from FGMs to porous filters

Large • Customised SPS systems 2010~ • Cost effective 5th Generation • High reliability SPS Process • Sinter Land Inc.

2001~ 4th Generation • 4 Processes SPS Process • 5 Basic production systems 1989~ • Sumitimo/SPSS • Industrialisation, 1962~ 3rd Generation: expanding applications st 1 Generation: Spark Plasma

Size effect Size Spark Sintering Sintering • High & low-pressure system • JAPAX Inc. • Sumitomo Coal • Large DC pulsed current Mining Co., Ltd. • Homogeneity/high density 1986 • High repeatability 2nd Generation: Plasma Activated Sintering (PAS) • Low-pressure system • IJR Inc (Inoue JAPAX • Small DC pulsed current Small Research Inc) Low High Shape effect: Functionality, reproducibility, productivity

Fig. 2 Historical progress of the Spark Plasma Sintering method and technology

A story of continual method for sheet metals [4]. These tion SPS system. The process was innovation processes are considered as the further developed by Inoue, resulting origin of the Hot Pressing (HP) tech- in a second generation technique Initial studies, dating back to around nique, where a high-frequency induc- known as Plasma-Activated Sintering 1910 in Germany, report a process tion heating method is applied. (PAS) released in 1986. Thereafter, where an electric energising tech- It was in the 1960s that a method in 1989, the Spark Plasma Sintering nique was applied to consolidate of Spark Sintering (SS) was developed method was introduced by Sumitomo a powder material. In the USA, a by Dr Kiyoshi Inoue of JAPAX Inc., Coal Mining Co., Ltd, Japan [7], being few years later in 1933, G F Tayler Japan [5, 6]. As shown in Fig. 2, this recognised as the third generation patented the first resistance sintering is now referred to as a first genera- of large DC pulse applied sintering techniques. Ongoing R&D for the implementa- Conventional reaction sintering tion of SPS methods and systems was initiated to design practical Reaction sintering Self-propagating high hardware and software for industrial temperature synthesis (SHS) applications. The development of Pressureless small- to medium-sized box-type sintering Thermal plasma sintering (conventional) experimental use SPS systems for new materials preparation, Atmospheric Microwave, Milliwave sintering and single-head open-type limited sintering production systems, followed. From Vac. Air, Ar/N2 Sintering inert gas Hot Pressing (HP) 2001 to 2009, as the fourth-genera- Methods tion technology developed to accom- Solid Spark Plasma Sintering (SPS) modate for product manufacturing, compaction five basic styles of SPS production Ultra high-pressure sintering systems emerged to suit medium- to Pressurised mass-production scales [8]. In addi- sintering tion to sintering, SPS technology also Hot Isostatic Pressing (HIP) found application in solid phase diffu- Gas sion bonding and joining [9], surface compaction High pressure gas reaction sintering modification (treatment) [10] and a synthesis technique, for example, of a Fig. 3 Typical classification of sintering methods single-crystal fabrication.

After 2010, the progress of SPS P technology was such that new, Oil pressure/ advanced SPS systems are now seen Upper electrode AC servo motor/ as being fifth-generation machines. pneumatic system Customised SPS apparatus, along with more practical manufacturing Powder applications, offer high reliability and Upper punch reduced production costs. Controller/computing Thermocouple Die A further interesting technology, and/or Digital derived from the ongoing develop- radiation Lower generator thermometer punch On-off DC pulse ment of SPS, is the emergence of Temperature Flash Sintering and Flash-SPS, a Vacuum Pressure category of Electric Current Acti- chamber Current-voltage Vacuum vated/assisted Sintering [3,11]. Still Lower electrode Longitudinal displacement under research, Flash Sintering could prove an innovative future technology. P

Fig. 4 Basic theory of the SPS process The Spark Plasma Sintering process Electric current Particle

The Spark Plasma Sintering process enables sintering and sinter-bonding, at low temperatures and at high speed. The technique, a form of pressurised sintering as seen in Fig. 3, involves the application of a high-energy, low-voltage electrical current, believed to result in a ‘spark Joule plasma’ phenomenon in the powder. heat (inside wall) (inside Although the precise mechanism of die Sintering the spark plasma remains unclear, many years of research by many different material researchers has resulted in a number of theories Discharge [12-16]. One of the most accepted explana- Fig. 5 ON-OFF DC pulsed current path and pulsed current flow through powder tions is based around the illustration particles in Fig. 4 where, once compacted and still under pressure, an on-off DC pulse voltage, at high current, is applied to the powder using a special pulse generator. It is understood that the electrical discharge results in a high-temperature spark plasma, up to several thousand degrees centi- grade, generated momentarily at the initial stage of energising. This forms uniformly throughout the compact and the generated heat fuses, puri- fies and activates the surface of the powder particles (Fig. 5). The initial stage of the pulse energising results in a discharge between the powder particles and between the powder and the graphite die wall surface (Fig. 6). When sparking occurs, a high-temperature sput- Fig. 6 The sintering stage in a graphite mould and vacuum chamber

Pulse voltage Phenomenon Effects Practical advantage

Generation of spark plasma Surface activation Low-temperature, short-time • Evaporation, melting & sintering purification ON High-speed diffusion, Generation of spark high-speed material transfer Sintering of hard-to-sinter impact pressure material (without catalyst), • Local stress and sputtering bonding of dissimilar materials Generation of Joule heat Efficient heating, plastic • Local high-temperature deformation promotion generation

High-density energy supply Short-time sintering Action of electric field • High-speed ion migration Dispersed movement Uniform sintering - short time of discharge point Efficient generation of Sintering of amorphous pulse voltage and current Quick cooling of materials intergranular bonding Sintering of metastable OFF phase Thermal diffusion Quick cooling of • Heat transfer from high- intergranular bonding temperature generating point Low-temperature sintering

Fig. 7 Effects of ON-OFF DC pulse energising

tering effect is generated by spark plasma and spark impact pressure. This works to eliminate adsorptive gases and oxide films and impurities existing on the surface of the powder particles. The action of the electromagnetic field enhances high-speed diffusion due to the electro-migration effects of ions. A Joule heating stage, caused by the passage of electric current through the powder whilst under mechanical pressure, further assists in the SPS process. The intense joule heating effect can often result in localised high-temperature generation, and therefore leads to localised vaporisation or cleaning of powder surfaces. Such a phenomenon ensures a favourable path for current flow. Further effects of the on-off pulse DC voltage are shown in more detail in Fig. 7.

Configuration of an SPS system

The configuration of a typical SPS system consists of a compacting Fig. 8 This medium-sized 5th Generation SPS system produced by Sinter press with a vertical, single-axis pres- Land Inc, Japan, offers high-precision process control and short cycle times. surisation mechanism, incorporating Systems such as this can be used with multiple materials and offer wide specially designed punch electrodes temperature ranges (Courtesy Sinter Land) made from graphite. The system can

Fig. 9 World’s largest semi-tunnel type automatic SPS production system has three vacuum chambers, 6 MN press with a pallet-type special conveyer, and inverter-type 40,000 A DC pulse generator (Courtesy Sinter Land)

incorporate a water-cooled vacuum In order to meet different produc- Development of pulse generators chamber, a vacuum/air/argon-gas tivity levels, there are typically five Presently, there are two basic types of atmosphere control mechanism, a options to consider. These include: DC pulse generator for SPS appa- special DC-pulsed power generator, multi-head, batch, tunnel, rotary and ratus, thyristor-type and invertor-type Z-axis position measuring and shuttle-type SPS systems. In addi- power supply. Fig. 10 shows examples control unit, temperature measuring tion to these, scaling-up process, of typical on-off pulse waveforms and and control units, an applied pres- automatic handling and powder different pulse width and ratio. The sure display unit, a data analysing stacking equipment for materials waveform, max./min. on-time/off-time unit and various safety interlock and process optimisation have also pulse width, peak current, frequency, devices. A typical 5th Generation been developed [17]. duty factor settings, control system medium-sized system can be seen in Fig. 8. This model is ideally suited to R&D work, as well as prototype and product manufacture.

Production-scale SPS systems Custom built SPS systems are also available today, as well as large production-based machines such as the example seen in Fig. 9. The move to production-scale SPS systems requires consideration of many factors. The cost and development of optimum systems will depend on production strategies, including the required cycle time, technologies to support scale expansion, mass- production, automation and numerical control systems. There is also the development of process technologies for high functionality, reproducibility, uniformity and structural control. In ON-time: 30 ms OFF-time: 10 ms ON-time: 10 ms OFF-time: 30 ms addition, pre- and post-processes for manufacturing must be considered. Fig. 10 Typical wave form of a thyristor-type pulse generator (ON-OFF ratio in 50 Hz)

Classification Materials for SPS processing

Metals Fe, Cu, Al, Au, Ag, Ni, Cr, Mo, Sn, Ti, W, Be, C Virtually any metal possible

Oxides Al2O3,Mulite, ZrO2, MgO,SiO2, TiO2, HfO2

Carbides SiC, B4C, TaC, TiC, WC, ZrC, VC

Ceramics Nitrides Si3N4, TaN, TiN, AlN, ZrN, VN

Borides TiB2, HfB2, LaB6, ZrB2, VB2, MgB2

Fluorides LiF, CaF2, MgF2

Si3N4+Ni, Al2O3+Ni, ZrO2+Ni

Cermets Al2O3+Ti, ZrO2+stainless steel, Al2O3+stainless steel WC+Co, WC+Ni, TiC+TiN+Ni, BN+Fe,

TiAl, MoSi2, Si3Zr5, NiAl Intermetallic compounds NbCo, Nb3Al, LaBaCuSO4, Sm2Co17 Other materials Organic materials (polyimide, etc.), FRM, FRC, CNT composite materials

Table 1 Suitable materials for SPS process

2400 and energy consumption vary between each system. Each pulse generator Al O 2300 2 3 has its own advantages and should be chosen based on the desired purpose 2200 and usage of the SPS system. 2100 The majority of SPS systems installed in universities, national insti- 2000 tutes and private companies employ the thyristor-type pulse generator, due 1900 Pure nano-SiC Hardness HV(1000) Hardness Powder particle size: 30 nm to a rich reference database on SPS 1800 R.D: 99.4% and higher reliability of power supply No binder mHV: 2380 hardware. The invertor type, with a Binder addition Diameter: 20 mm Grain size after SPS: 100 nm Pulse Width Modulation (PWM) control, 0 PLS HP HIP SPS offers a lower power consumption Sintering method and a more compact size, which could make it a more attractive option for Fig. 11 Nano-SiC compact by SPS and Al O HV hardness distribution behaviour 2 3 economical low-cost production. The sintered by various methods development of pulse generators is still ongoing.

SPS HP Sintering Temperature gradient sintering ◎ × Materials Grain boundary controlled sintering ◎ × The SPS process is suited to a number Fine crystalline structure controlled sintering ◎ × of materials, including conductive and non-conductive powders. An Temperature rise rate ◎ × example of suitable materials for SPS Temperature rise time Fast Slow is provided in Table 1; these include Sintering time Holding time Short Long metals, ceramics, cermets, intermetallic compounds and others. Homogeneous sintering ○ ○ When using non-conductive Expandability ◎ △ materials, where no sparking occurs between powder particles, it is consid- Productivity ◎ △ ered that the effect of on-off DC pulse Investment in equipment ○ △ current still exists, energising parti- Running cost cles, which results in an enhancement ◎ △ of the sinterability and densification ( excellent | good | fair | difficult) ◎ ○ △ × rate of the material. The large pulsed Table 2 Comparison of the characteristics of SPS and HP sintering energy generates an electro-magnetic

field effect, such as an electro-migration, and preferential orientation of Load crystalline structure [18]. A: Material A B: Material B Comparing traditional sintering processes to Spark Plasma Sintering

The method of applying heat directly Powder to the compact results in extremely DC Pulse Power high heating and cooling rates, and is therefore capable of reducing sintering time from hours to minutes. Compared with conventional sintering, the SPS method has demonstrated superior material properties, as it can offer a structure tailoring effect, minimise grain growth, enhance electro-migration and provide a strong Load preferential orientation effect. A comparison of various sintering Fig. 13 A typical fabrication process for FGMs by Spark Plasma Sintering techniques and the resulting HV Vickers hardness is shown in Fig. 11 for an Al2O3 example. The results indicate that SPS offers hardness equal Examples of SPS process Examples of bulk FGM to and greater than processing by HIP applications compacts, produced by Spark or conventional hot press sintering. A Plasma Sintering, are demon- comparison of specific characteristics strated in Fig. 12. Seen from the of the SPS method, against conven- Functionally Graded Materials left, (a) ZrO2(3Y)/stainless steel tional Hot Press (HP) sintering, is Functionally Graded Materials compact with six interlayers, (b) shown in Table 2. (FGMs), often referred to as having ZrO2(3Y)/nickel compact with seven As a sintering technique, SPS has ‘dream’ properties, are advanced interlayers, (c) copper/stainless drawn considerable attention as one materials characterised by a steel compact with five interlayers, the newest rapid sintering methods. gradual variation in composition (d) aluminium/polyimide compact The novel process also benefits from and structure, resulting in changes with three interlayers and, on the low power consumption of between to the properties of the component. right, (e) Al2O3/titanium compact 1/5 and 1/3 that of conventional The original concept of FGMs was with three interlayers. The SPS sintering techniques, such as pres- proposed in 1984 by material scien- process resulted in full-density sureless sintering, hot press sintering tists in Japan during an aerospace sintered compacts, with no micro- and Hot Isostatic Pressing (HIP). research project. cracks detected.

(a) (b) (c) (d) (e)

Examples of bulk FGM compacts Enlarged cross-section ZrO (3Y)/410L stainless steel a) ZrO /stainless steel,b) ZrO /Ni, c) Cu/stainless steel, 2 2 2 of Al/Polyimide FGM 6 layers (left) and 21 layers d) Al/Polyimide and e) Al2O3/Ti

Fig. 12 Typical examples of bulk FGMs

Utilising a temperature gradient Horn-tip tool for an ultrasonic of 1573 K, at a pressure of 30 sintering technique of SPS, the homogeniser MPa, resulted in the lowest 17 process has successfully created Ultrasonic homogenisers act mg wear amount following a 50 h a wide range of bulk FGMs with through the rapid vibration of a homogenising operation test. multiple layers, including various titanium probe, or horn, transmitting The life span of the new horn-tip

systems of ZrO2/stainless steel, ZrO2/ ultrasonic energy to the sample. The has proved to be around eight-to-ten

TiAl, ZrO2/Ni, Al2O3/stainless steel, vibration causes homogenisation times greater than conventional

Al2O3/Ti, Al2O3/Ti-6Al-4V, WC/stain- directly through the ultrasonic forces options, without cracking, peeling less steel, WC/Co, WC/Ni, Cu/stain- as well as through cavitation, where or breakage. It is expected that

less steel, SiO2glass/stainless steel, the rapid formation and collapse of remarkably less contamination will Al/polyimide resin, Cu/phenol resin bubbles occurs as a result of the present a highly reliable production and Cu/polyimide resin materials, vacuum formed when the probe process, and the available large- etc. [19-22]. retracts. Conventional titanium sized horn-tip encourages higher Fig. 13 shows a schematic illustra- horn-tips, although chemically output power oscillation with much tion of an SPS temperature gradient stable and mechanically easy to better productivity. die assembly and an example of produce to the desired shape, result

multi-layered ZrO2(3Y)/stainless steel in low wear resistance, can lead to Sputtering target fabrication FGMs compact, which contains a 3 contamination and have a short life With the SPS process, highly-dense mol.% yttrium partially stabilised span. Alternative options, such as sintered products can be fabricated

zirconia (PSZ) powder, a 410L stain- brazed ZrO2 plates on a Ti body, can at a much lower temperatures and less steel powder and mixed powders result in weakness at the brazed with shorter heating up and holding of the two as intermediate layers with layer. Monolithic ceramic horn-tips times, compared with hot pressing a different volume fraction. The FGM have good hardness, but are brittle and HIPing. Thus, sputtering target powders were stacked in a graphite and can result in a short life span. materials are another application temperature-gradient die of 20 mm The FGM horn-tip shown in field for SPS that can provide positive internal diameter. The stainless steel Fig. 14 is based on the optimised results. Indeed, several companies

powder has an average particle size sintering conditions of Al2O3/ have developed a profitable business

of 9 μm while the PSZ powder is of Ti-Ti, with a five layered ZrO2/Ti/ using SPS in this way. granulated particles with an average Ti-6Al-4V alloy FGM developed for Fig. 15 shows a typical example particle size of 50 μm (its crystalline the structure. The ceramic-metal of a large-sized metallic sputtering size is 350 Å). The sintering pres- material achieved a hardness target with a diameter of 350 mm sures used were 20–40 MPa, SPS of HV 1364 and, due to the the produced by a large-size SPS temperatures of 1243–1293 K, with high hardness at the surface, system. When producing this part by a temperature rise rate of 50 K/min offered greatly improved corrosion SPS, productivity was approximately measured near the stainless steel resistance during the cavitation seven-to-eight times higher than layer [20, 21]. process. A sintering temperature conventional sintering of HP and HIP

ZrO2 100%

ZrO2 70% - Ti 30% ZrO2 50% - Ti 50% Oscillator ZrO2 20% - Ti 80%

Ti-6Al-4V 100%

Horn Tip Oscillator Converter Horn Tool / Tip (from Ti alloy to FGMs)

Fig. 14 Ultrasonic homogeniser and ZrO2/Ti alloy system FGM horn tip tool (manufactured by Mitsui Electric Co.,Ltd, Japan)

Comparison of Sintering time 9 8 7 6 5

time 4 3 2 1 0 SPS HP/HIP Axis Title SPS Sintering temperature: 1373-1473 K Materials example: CrB2, CrB, SiC, SiO2, Ta 2O5, ITO, BaTiO3, PbTiO3, TiN,

Relative density: 99-100% Material: Ru TiAl, Ti-Al-Si, TiTa, Mg2Si, Ru, RuCo, NiCr, others

Fig. 15 Example of Ø350 mm large-size metallic sputtering target material

Material: Al2O3 Material: Al2O3 Material: pure WC (no additives) Material: SiC (with additives) R.D: 98-99% R.D: 99-100% R.D: 99-100% R.D: 99-100% Dimensions: Ø 300 x 10 mm Dimensions: Ø 200 x 10 mm Dimensions: Ø 100 x 16 mm Dimensions: Ø 150 x 12 mm

Fig. 16 Example of large-size ceramics by SPS

processes. Also, due to the obtained the cost-effective production of high from a binderless pure-tungsten finer grain size of the SPS sputtering performance aspherical glass lenses carbide (WC single phase, HV 2600) target materials, superior sputtering used in the digital cameras. To meet material. performances can result where, for this need, SPS has been utilised in The SPS moulds were homog- example, no splashing phenomenon the production of moulds used to enously consolidated in nano- occurs in the coating process. form the aspherical glass lenses. The structured fine grain size material.

Large-sized oxide (Al2O3, ZrO2, mould consists of three pieces; an By using an ultra-fine grinding

SiO2), carbide (WC, SiC, B4C), nitride upper punch, lower punch and sleeve machine, a superior mirror surface

(Si3N4) and boride (TiB2) ceramic die part. Fig. 17 shows examples of finish, with a roughness of Ra 2-6 materials have also been fabricated such moulds used commercially in nm, can be obtained. The advan- homogenously with finer grain size the optics industry, which are made tages of SPS pure WC are that no and almost full density. The samples shown in Fig. 16 were investigated by SEM and it was observed that almost no residual micro pores and no cracks were present in the sintered compacts.

Pure WC (tungsten carbide) aspheric glass lens mould The growing demand for in-vehicle camera systems for monitoring road conditions, as well as general surveillance and security cameras, has greatly increased the need for Fig. 17 Examples of pure WC Aspheric glass lens mould materials

General SPS sintered Advantage of SPS commercial nozzle sintered nozzle products Vickers hardness (HV) 900 - 1100 2100 - 2200 High hardness Relative density (%) 91 100 High density Mirror finished Mirrored Surface Rough surface by near-net surface shape Material: Al2O3 Length: 60mm Ten times longer Outer dia. (Tapered):30/15mm Lifetime One day Ten days Inner dia. (Straight):6mm lifetime

Fig. 18 Comparison of SPSed nozzle and other commercial product

additives are used in the solid-phase compared to a conventional nozzle a three dimensional shape for an sintering and a finer grain size as with HV 900-1100. Produced to near- automotive engine piston compo- well as higher oxidation resistance is net shape accuracy, a Ra 0.64 μm nent, by a high-speed forging press achieved, compared to conventionally surface roughness was obtained. machine, it was demonstrated to produced binderless WC materials. provide full forming for lengths of By running a 10 h oxidisation test in Emerging super-plasticity and high 75 mm within 15–20 seconds per an atmospheric furnace at 973 K, specific strength of aluminium-Si stroke with the strain rate of 10-2S-1 a 30-60% better oxidisation rate in alloy materials or higher. The results indicate the volume (g/cm3) was demonstrated. The SPS process can be used to phenomenon of ‘super-plasticity’ achieve nanostructured dense occurred, improving the ductility and Complex near-net shape forming of high-silicon/aluminium alloys. The elongation of the sintered compact.

Al2O3 blasting nozzle rapidly solidified Al-Si powder, of The tensile strength was 350 MPa

An example of an Al2O3 ceramic average particle size 120-150 μm, and it was approximately 1.5 times nozzle, used in sand-blasting appa- silicon content 12–17% or higher stronger than a conventionally forged ratus, is shown in Fig. 18. Compara- and nanocrystalline structure, component. This Al-Si alloy with tive testing between a conventionally was successfully consolidated into nanostructural material is expected manufactured nozzle and one made Ø 60–120 mm x 40–60 mm cylindrical to find wide applications in various using SPS process, was under- compacts with between 600–800 nm electric appliances, electronics and taken in real-time blast operating grain size as shown in the TEM automotive components [23].

conditions. The SPSed Al2O3 nozzle micrograph in Fig. 19. The sintered achieved ten times longer life span compacts, with relative density Porous materials prepared by SPS than a conventionally sintered one of almost 100%, were obtained at The fabrication of both metallic and produced in an atmospheric pres- temperatures of 723–773 K, applied ceramic porous structures is another sureless sintering furnace. pressures of 100–150 MPa and heat application where SPS could offer The SPS nozzle is produced up and holding time of 20 min. When advantages over existing sintering without post processing and has the Ø 60 mm x 40 mm nanostructure methods. In this example, the pure

Vickers hardness of HV 2100-2200, SPSed bulk body was formed into titanium and ZrO2(3Y) bead struc-

RapidlyRapidlyRapidly solidifiedsolidified ppowowderder PowderPowderPowder consolidation consolidationconsolidation SuperSuper plastic plasticplastic forming forminformingg TEMTEMTEM micrograph micrographmicrograph of ofof preparedpreparedpowder prepared by bybyby SPS SPSSPS byby forging ForgingForging press presspress machine machinemachine SPSed compactSSPSedPSed ccompompactact bybywater waterwater atomisation atomizingatomizing forfor automotiveAutomo Automottiivve e component componentcomponent

11μμmm

Fig. 19 Appearance of Super-plasticity on automotive component

TiTi beads beads ZrOZrO22(3Y)(3Y)beadsbeads

TiTi Neck Neck by by SPS SPS Rapidly solidified powder Powder consolidation Super plastic forming TEM micrograph of prepared by SPS by Forging press machine SPSed compact Rapidlyby water solidified atomizing p owder Powder consolidation Superfor Automo plastictiv formine componentg TEM micrograph of prepared by SPS by Forging press machine SPSed compact by water atomizing for Automotive component

1μm

tures seen in Fig. 20 are formed by applying a low sintering pressure in the range of 0–5MPa, demon- strating that it is possible to obtain high porosity with higher bonding Ti beads ZrO2(3Y)beads strength at the neck portion. Potential commercial applications for this process include ZrO (3Y) beads materials for a bio-reactor, filters, TiTi beadsbeads ZrO2(3Y)2 beads artificial bone joints, vent core materials for a plastic moulding die, electric and hybrid-electric vehicle applications, solid oxide fuel cell (SOFC) batteries, thermoelectric semi-conductors, heat Ti TiNeck neck byby SPS SPS spreaders for thermal conductive components and others. Pre-heating stage Sintering stage Cooling Cooling/Air introduction stage Fine-WC/Co hard alloy FGMs for VacuumFig. exhausting 20 TiExamples Neck sof tageby porous SPS material die & mould and wear-resistant Pre-heating stage Sintering stage Cooling Cooling/Air introduction stage materials industries VacuumInlet exhausting stage Outlet As a typical high-wear resistant Pre-heating Sintering Cooling cooling/air introduction material, WC/Co or WC/Ni systemInlet Vacuum exhausting Outlet cemented carbides are now widely used in various press-stamping Inlet Outlet dies and cutting tools for industrial applications. Although the fabrication of WC/Co hard alloys usually takes many hours, with the development of new automated SPS systems, it is proving possible 2 pieces and 20 min/cycle to sinter such materials in a 10 times continuous operation significantly shorter period, taking advantage of the characteristics inherent in SPS rapid sintering technology. Table 3 highlights the typical mechanical properties of SPS fine WC system hard alloy products. Fig. 21 shows the production machine’s system configuration and an outside view of the fully- Fig. 21 System configuration and outside view of tunnel-type SPS and large- automated five-stage chamber- size 100×70 mm WC/Co cemented carbide hard-alloy compacts fabricated in type continuous SPS system. Using 10 times continuous operation this full tunnel automated system and optimised conditions, large square-shaped WC/Co cemented Transverse Product Co WC pdr. Fracture Density Hardness rupture carbide hard alloys, with dimen- code content grain size toughness g/cm3 mHV strength sions of 70 mm × 100 mm × 5-20 name wt.% μm K1C MPa mm, were homogeneously fabricated in a shorter sintering time TC-05 <2 <0.5 15.2 2350 2300 6.2 and with a finer grain size than TC-10 <4 <0.5 15.0 2150 2640 6.5 conventional sintering methods. TC-20 <6 <0.5 14.8 2050 2940 7.3 The fine-WC/Co hard alloys M78 0 <0.2 15.4 2600 1500 5.1 obtained by SPS show higher hard- WC100 0 <0.08 15.6 2700 1470 5.6 ness, transverse rupture strength NC100 0 <0.5 15.4 2570 1180 5.4 and fracture toughness, than those obtained by conventional methods. Table 3 Typical mechanical properties of Fine WC/Co hard alloys by SPS

2500 WC 0.5 μm/Co 6%

55 5 WC0 5 m 6 Co 2000 . μ - %

WC 3.5 μm/Co 14% 77 7 WC3.5μm-14%Co 1500 WC 5 μm/Co 20% 88 8 WC5.0μm-20%Co 1000

500 0 0 WC9.0μm-20%Co

WC 9 μm/Co 20% 22 20 0 Micro vichkers hardness (mVH) hardness vichkers Micro 0 5 10 15 20 25 Distance from surface (mm) Fig. 22 Large-size WC/Co FGM fabricated by SPS (100 mm × 100 mm × 40 mm) and profiles of micro-hardness on Co content graded cemented carbide by SPS

WC/Co and WC/Co/Ni FGMs for cut electrical discharge machine layer than a monolithic WC/Co hard industrial applications to remove smaller pieces of the alloy material. When assembled to In the first example, a WC/Co FGM material. As shown in Fig. 23, the form a press stamping progressive block, compositionally graded by smaller piece of WC/Co FGM was die set, the FGM sample achieved cobalt content and measuring 100 ground to form the specified profiles. an approximately three and a half to × 100 × 40 mm, was produced using The fine WC/Co FGM hard alloy ten times longer life time compared SPS within an hour (Fig. 22) [32, demonstrated high hardness in the with conventional commercial WC/Co 33]. The FGM was then machined top layer and higher strength and cemented carbides. by numerically-controlled wire- fracture toughness in the bottom In a further project, a weldable WC/Ni FGMs screw, used in an extruding machine, was also produced using the SPS process (Fig. 24). The working life proved to be over three times longer than that of the conventional screw, resulting in more than 3000 h service compared to around a typical 800 h in the conventional screw. This FGM screw has proved a successful example of SPS manufacturing and has now been in operation for a number of years at Japan’s Hokkaido Electric Power company [24].

Diamond dicing blades for cutting Fig. 23 Example of press stamping die and punch made of WC/Co FGMs for tool industry electronic component The manufacture of diamond dicing blades, for use in the cutting tool and wear-resistant materials industry, is a further example of how the SPS process can offer distinct advantages. As shown in Fig. 25, metal bonded dicing blades of 100/150 mm diameter and 0.35/0.4 mm thickness can be produced with a flatness level within ± 20 μm and minimal residual stresses. Obtaining such flatness by SPS eliminates a grinding process. The sintered Fig. 24 Weldable WC/Ni FGMs tile and the FGMs screw product for the WC/Co plate has relative density extruding machine 99-100% and a Young’s modulus

500-580 GPa was attained under Sintering Powder SPS temperature of 1473–1523 K. Material To achieve series production, in this (or Green body) example continuous SPS operation Multi through multiple work shifts per Layers: day resulted in the simultaneous n=5 ~ 20 fabrication of 15–20 plates per possible batch.

Graphite Other Industrial Applications Spacer Although not discussed in this article, research into the use of SPS Outer Diameter Ø 100/150 mm in other categories of materials Inner Diameter Ø 40/60 mm includes MMC/FRC/FRM composites, thermoelectric semiconductors Thickness 0.35/0.40 mm of SiGe, Bi Te , FeSi , CoSb , MnSi , 2 3 2 3 2 SPS sintering temp. 1473 ~ 1523 K Mg2Si systems for clean energy

generation, Nd-Fe-B, Sm2Co17 and Sintering Pressure 40 ~ 50 MPa ferrite for magnetic materials, Relative Density 99 ~ 100% MgB2 superconducting materials Young Modules 500 ~ 580 GPa [25], BaTiO3 [26], PbTiO3 dielectric materials, shape memory alloys, Flatness <± 20 μm solid cell materials, glassy metals, optically functional materials and Fig. 25 WC/Co sintered very thin plate with diamond of Dicing Blade nanocrystalline materials [27]. All could be promising candidates for industrial SPS applications [28]. Applications for SPS 3D forming terms of the high energy density of References methods and titanium/hydroxyapa- dynamic sintering, further study of tite (HAP) for biomedical applica- these characteristics will lead to tions could also move from the the successful advancement and [1] M. Tokita, “Development of R&D/prototype level into practical expansion of SPS applications for Advanced Spark Plasma Sintering use in the near future [29,30]. commercial production. The SPS (SPS) Systems and Its Industrial process has the potential to become Applications”, Ceramic Transaction a major manufacturing tool in the Vol.194, Am. Ceram. Soc., Wiley- Summary & outlook automotive, electronics, mould Interscience, (2006) 51-60 & die, tooling, clean energy and [2] Z.A. Munir, U.Anselmi-Tamburini, In this article, the history and aerospace industries, to name just M. Ohyanagi, “The effect of electric fundamentals of SPS, as well as the a few, with opportunities in both field and pressure on the synthesis wider availability of SPS systems high-value added, small scale and and consolidation of materials: A and related industrial applica- mass-production markets. review of the spark plasma sintering tions have been discussed. Typical method”, J. Material Science, 41 advantages of SPS processing are (2006)763-777 indicated in the synthesis of FGMs, Author [3] S. Grasso, Y. Sakka and G. Maizza, nanocrystalline materials and wear- “Electric current activated/assisted resistant hard materials. Due to the Masao TOKITA (Ph.D) sintering (ECAS): a review of patents versatility of SPS, the remarkable Head of SPS R&D Center 1906-2008”, Science and Tech- and rapid growth in the number of Senior Managing Director nology of Advanced Materials, Vol. presented papers and patents in NJS Co.,Ltd. 10(2009)1-24 the last decade should be noted, 301 Office Shinyokohama, resulting from a new, worldwide [4] G.F. Taylor, “Apparatus for making 2-14-8, Shinyokohama, adoption of SPS technology in both hard metal compositions”, U.S. Kouhoku-ku, Yokohama, the scientific community and the Patent No. 1, 896.854 (1933) Kanagawa, 222-0033, industrial sector. [5] K. Inoue, “Electric Discharge Japan SPS features an electrical Sintering”, U.S.Patent No energy concentration at areas website: www.njs-japan.co.jp 3,241,956(1966) ( Ser. No. 247,387 where current flows easily. In email: [email protected] filed 1962)

[6] K. Inoue, “Apparatus for electri- [16] T. Misawa, N. Shikatani, Y. [24] M. Tokita, “Development of cally sintering discrete bodies”, Kawakami, et al., “Influence of Square-Shaped Large-size WC/Co/ U.S.Patent No 3,250,892 (1966) Internal Pulsed Current on the Ni system FGM Fabricated by Spark [7] M. Tokita, “Trends in Advanced Sintering Behavior of Pulsed Current Plasma Sintering (SPS) Method and SPS Spark Plasma Sintering Systems Sintering Process”, Material Science Its Industrial Applications”, Mate- and Technology”, J. Soc. Powder ForumVols.638-642, (2010)2109-2114 rials Science Forum, Vols.492-493 Technology, Jpn., 30[11] (1993)790- [17] Y. Makino, “Crystallographic (2005)711-718 804 behaviors of nano-powder anatase [25] J. Schmidt, W. Schnell, Y. Grin. [8] M. Tokita, Development of Auto- consolidated by SPS method”, R. Kniep, “Pulse plasma synthesis matic FGM Manufacturing Systems CeramicTransaction Vol. 194, Am. and chemical bonding in magne- by the Spark Plasma Sintering (SPS) Ceram. Soc., Wiley-Interscience, sium diboride”, Solid State Sciences, Method”, Ceramic Transaction Vols. (2006) 301-312 5(2003)535-539 114, Am. Ceram. Soc., (2001) 283-290 [18] M. Tokita, “Method and system [26] T. Takeuchi, M. Tabuchi, Y. [9] Y. Miyasaka, M. Tokita, H. Kara- for automatic electrical sintering”, Suyama and H. Kageyama, “Prepara- sawa, F. Nishiyama, “Electric joining US. Patent No 6,383,446 B1 (2002) tion of Dense BaTiO3 Ceramics with methods and apparatus and a joined [19] F. Watari, H. Kondo, S. Matsuo, Submicrometer Grains by Spark unit of members”, U.S.Patent No. 6, R. Miyao, A. Yokoyama, M. Omori, T. Plasma Sintering”, J. Am. Ceram. 515, 250(2003) Hirai, et al., “Development of Func- Soc., 82 [4] (1999)939-943 [10] K.A. Khor, X.J. Chen, S.H. Chan, tionally Graded Implant and Dental [27] U.Anselmi-Tamburini, J.E. Garay, L.G. Yu, “Microstructure-property Post for Bio-Medical Application”, Z.A. Munir, “Fast low-temperature modifications in plasma sprayed Material Science Forum Vols.423- consolidation of bulk nanometric 20 wt% yttria stabilised zirconia 425(2003)321-326 ceramic materials”, Scripta Mate- electrolyte by spark plasma sintering [20] M. Tokita, “Development of rialia, 54(2006)823-828 technique”, Materials Science and Large-Size Ceramic/Metal Bulk [28] Y. Makino, K. Mizuuchi, M. Tokita, Engineering A366, (2004) 120-126 FGM Fabricated by Spark Plasma Y. Agari, M. Kawahara and K. Inoue,” [11] M. Yu, S. Grasso, R. Mckinnon, T. Sintering”, Materials Science Forum, Synthesis of new structural and func- Saunder, M.J. Reece, Adv. in Applied Vols.308-311(1999)83-88 tional materials by SPS processing”, Ceramics, 116 [1], (2016), 24-26 [21] M. Tokita, M. Kawahara, Materials Science Forum, Vols.638- 642 (2010)2091-2096 [12] K. Ozaki, K. Kobayashi, T. M. Sonoda, M. Omori, A. Okubo Nishio, A. Matsumoto, A. Sugiyama, and T. Hirai, “Preparation and [29] M. Tokita, “The potential of Spark “Sintering Phenomena on Initial Triborogical Characterization of Plasma Sintering (SPS) method for Stage in Pulsed Current Sintering”. J. ZrO2(3Y)+20wt%Al2O3/410L Stain- the fabrication on an industrial scale Jpn. Soc. Powder and Powder Metal- less Steel Composite Functionally of Functionally Graded Materials”, lurgy, 47(2000)293-297 Graded Material Fabricated by Spark Advances in Science and Technology Plasma Sintering Method”, J. Jpn. Vol. 63 (2010)322-331 [13] Z. Shen, M. Johnsson, Z. Zhao Soc. Powder and Powder Metallurgy, and M. Nygren, “Spark Plasma [30] M. Tokita, “Development of ZrO2/ 46 [3] (1999)269-276. Sintering of Alumina”, J.Am.Ceram. Ti alloy FGMs Horn tip tool for Ultra- Soc. 85[8] (2002)1921-27 [22] M. Belmonte, J.Gonzales-Julian, sonic Homogenizer by Spark Plasma P. Miranzo, M. I. Osendi, “Continuous Sintering (SPS) method”, proceedings [14] X. Song, X. Liu and J. Zhang, in situ functionally graded silicon of ISFGMs2018 15th International “Neck Formation and Self-Adjusting nitride materials”, Acta Materialia symposium on Functionally Graded Mechanism of Neck Growth of Vols.57, 9(2009)2607-2612 Materials, Kitakyushu, Japan (Aug. Conducting Powders in Spark Plasma 2018) O-17/1-6 Sintering”, J. Am. Ceram. Soc., 89 [2] [23] N. Kuroishi, “High-Strain-Rate (2006)494-500 Superplasticity in Sintered Pre- Forms Produced by Plasma Spark [15] R. Chaim, “Densification mechanisms in spark plasma sintering of Sintering”, Proc. NEDO Int. Sympo. nanocrystalline ceramics”, Materials on Functionally Graded Materials, Tokyo, Japan, (1999) 67-74 Science and Engineering, A 443 (2007) 25-32

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