HIP Technology Developments in PM Aluminium MPIF Award Winning Parts

POWDER a ll 2012 METALLURGY

Vol.1 No.1 Vol.1 Autum n /F Review

trends in HIP technology developments in PM aluminium MPIF Award winning parts

Published by Inovar Communications Ltd ipmd.net Publisher & editorial offices Inovar Communications Ltd 2 The Rural Enterprise Centre POWDER Battlefield Enterprise Park Shrewsbury SY1 3FE METALLURGY United Kingdom Editor & Publishing Director Review Paul Whittaker L ike many exceptional eminent innovators of the past, our pioneering metallurgists at Tel: +44 (0)1743 454992 Fax: +44 (0)1743 469909 Hoeganaes Corporation continue to set increasingly higher benchmarks in the eld of powder Email: [email protected]

metallurgy. Managing Director Nick Williams e continue to lead innovation in technologically advanced metal powders and processes that Tel: +44 (0)1743 454991 Fax: +44 (0)1743 469909 W Email: [email protected] A new magazine for the PM meet customers' ever-increasing demands for high performance materials solutions. These new processes have been a major factor in establishing powder metallurgy (PM) as the fastest growing Accuracy of contents industry metal forming process in the world. PM products we’ve developed with these processes allow Whilst every effort has been made to ensure the accuracy of the information in this publication, fabricators to produce parts with greater strength, higher densities, enhanced dimensional stability the publisher accepts no responsibility for Welcome to the first issue ofPowder Metallurgy Review, a new quarterly and with more complex geometries than ever before. errors or omissions or for any consequences magazine for the PM industry from Inovar Communications Ltd. arising there from. Inovar Communications Ltd cannot be held responsible for views or claims This new publication comes on the back of our highly successful weekly expressed by contributors or advertisers, which are not necessarily those of the publisher. ipmd.net e-newsletter, launched in October 2010 and now sent to more than 7000 PM professionals. Despite the success of our e-newsletter Reproduction, storage and usage in delivering PM industry news “as it happens”, we have launched this Single photocopies of articles may be made title in response to feedback from numerous industry professionals who, for personal use in accordance with national whilst appreciating the advantages of a weekly e-newsletter, also wish to copyright laws. Permission of the publisher and payment of fees may be required for all other have such information on the PM industry in a format that they can keep, photocopying. either digitally or in print, for future reference.

All rights reserved. Except as outlined above, Powder Metallurgy Review will therefore be available in both print and no part of this publication may be reproduced, digital formats, bringing together news and technology developments stored in a retrieval system, or transmitted from the ipmd.net website plus additional exclusive content. We will in any form or by any means, electronic, photocopying or otherwise, without prior specifically focus on developments in the global press and sinter PM permission of the publisher and copyright industry, including ferrous and non-ferrous components, hard materials, owner. PM high alloy steels, PM superalloys, diamond tools and sintered magnets, as well as HIP/CIP and powder forging. Submitting news and articles We welcome contributions from both industry As with its sister publication Powder Injection Moulding International, and academia and are always interested to hear about company news, innovative applications our mission is to not only provide relevant coverage of the industry and for PM, technology developments, research and its many players, but to present Powder Metallurgy in a positive light, as more. the dynamic, modern and successful advanced metal forming process that it is. Please send all submissions to Paul Whittaker; Email: [email protected] This launch issue will be distributed from our stands at Euro PM2012, Tel: +44 (0)1743 454992 Basel, and the PM2012 World Congress and Exhibition, Yokohama. From Subscriptions 2013, it will be published four times a year (Vol. 2 Nos. 1-4).

Powder Metallurgy Review is published on a quarterly basis. It is available as a free As well as distribution at PM events worldwide, each issue of Powder electronic publication, or as a paid print Metallurgy Review will be mailed to selected PM industry professionals subscription. The annual subscription charge for from our extensive International Powder Metallurgy Directory (IPMD) four printed issues is £85.00 including shipping. database. It will also be available to download, free-of-charge, in PDF Rates in € and US$ are available on application. format from the ipmd.net website. For those wishing to ensure that they Advertising opportunities receive every issue in print format, a subscription is available for £85 per Contact Jon Craxford, Advertising Director, to year (approximately $135/€105) including airmail shipping worldwide. discuss how we can help promote your products and brand, both online and in print. We look forward to receiving your comments on the contents and direction of the new magazine, and to receiving any relevant news or Tel: +44 (0) 207 1939 749 editorial that you wish to submit for publication in future issues. Fax: +44 (0) 1242 291 482 Email: [email protected] Paul Whittaker Design and production Editor, Powder Metallurgy Review Inovar Communications Ltd.

ISSN 2050-9693 (Print edition) ISSN 2050-9707 (Online edition)

Cover image © 2012 Inovar Communications Ltd. A 2012 MPIF award winning PM two- stage helical gear and spur pinion used in a power liftgate actuator, manufactured by Capstan Atlantic, Wrentham, Mass., ipmd.net USA (Photo courtesy MPIF)

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The future success for PM technology is to be found in the close interaction between application knowledge, design aspects, optimum process conditions and high-quality powder materials. Based on this notion we opened the door to our PoP Centre.

One example of how we extend the market for PM technology in the PoP Centre, is high load-carrying PM in this issuegears. We have already proven the concept and now advance our development activities even further.

Join us in the development of new powder based applications. 23 Recent trends in Hot Isostatic Pressing (HIP): 39 New alloy developments enhance PM Processing and applications aluminium application opportunities The processing of primarily large Powder Metallurgy The results of two separate Powder Metallurgy (PM) near-net shapes such as superalloys, tool steels, aluminium alloy developments, pursued through stainless steels, and titanium by Hot Isostatic Pressing collaborations between GKN Sinter Metals and (HIP) has been used extensively since 1970 and an Dalhousie University and aimed at two diverse types estimated 1000 HIP systems have been installed since of PM press/sinter application, were revealed in Ipsen delivers a step forward. that time. HIP systems are also used for defect healing presentations at PowderMet 2012. Dr David Whittaker of castings, diffusion bonding and cladding, and fully reviews these papers exclusively for Powder Metallurgy densifying hardmetals (cemented carbides). We review Review / ipmd.net. Backed by more than 60 years of thermal processing expertise, Ipsen’s new sintering furnace, TITAN® DS, trends in HIP process technology and application trends upholds our reputation for quality. Better performance and better features for less cost brings the MIM for powder materials. 45 Binder/lubricant developments enhance and Powder Metallurgy industry one step forward. Powder Metallurgy part quality and strength 31 North America’s Powder Metallurgy industry A presentation in the Special Interest Programme Benefits: Technical Information: maintains its growth momentum on Lubrication Science at PowderMet 2012 from • Shortest door-to-door cycle time • Work zone size 915 mm x 915 mm x 1,220 mm In comments delivered during the opening session Hoeganaes Corporation, USA, emphasised the message of PowderMet 2012, the International Conference on that the development of binder/lubricants has brought • Unbeatable price-to-volume ratio for = 1,020 liter (36” x 36” x 48”) Powder Metallurgy & Particulate Materials, Nashville, a range of compaction process control and dimensional • Hearth gross load weight capacity 1,350 kg (3,000 lbs) specialized MIM furnace June 10-13, Matthew Bulger, President of the Metal control benefits, and has been an important enabler • Precise process control for consistent • Maximum operating temperature 1,450°C (2,650°F) Powder Industries Federation (MPIF), stated that in in the enhancement of product densities and part quality • Temperature uniformity better than +/- 5°C (+/- 10°F) all materials, process and market sectors, the North strength levels through processes such as Warm Die American Powder Metallurgy industry has built on the Compaction. Dr David Whittaker reviews this paper • Short delivery time with rapid start-up -2 • Ultimate vacuum level <5 x 10 mbar (< 50 microns) growth momentum that began last year. exclusively for Powder Metallurgy Review / ipmd.net. • One global standard • Nitrogen, hydrogen and argon partial • Modular design allows for ease of pressure for operation up to 10 mbar (10 Torr) 33 Award winning parts demonstrate PM’s many regular features production flow optimization • Internal nitrogen or argon gas advantages for critical applications cooling up to 2 bar Winning parts in the MPIF’s 2012 Powder Metallurgy 5 Industry news Design Excellence Awards competition were announced at PowderMet 2012. We present all the award winning 48 Advertisers’ index For more information contact Ipsen at 1.815.332.3074 or [email protected]. components. 48 Events guide

Höganäs reports stronger Miba enjoys continued sales in Asia during Q2 sales growth

Commenting on the second quarter Following its best ever year in 2011/2012 with full year results for Swedish powder producer consolidated sales increasing by 35.6% to €592.6 million, Höganäs AB, CEO Alrik Danielsson Miba AG of Vorchdorf, Austria, reported that sales in the stated, “In current market conditions, first quarter of fiscal year 2012/2013 (February 1 to April 30) we are benefiting from our high expo- soared by a further 16% to €160.9 million compared with the sure to markets outside Europe. The same period last year. Purchasing and processing all types of volume recovery in Asia, our largest “The success of the past business year continued to market, continued after a 2011 nega- motivate us in the first quarter, and our volume of orders tively affected by the tsunami and Alrik Danielsson, remains satisfactory,” stated Peter Mitterbauer, Chairman flooding. As expected, Europe was of the Management Board of the Miba Group. Miba Sinter CEO and President of noticeably weaker due to decreasing Group accounted for 35% of consolidated sales, followed by powdered metal scrap Höganäs AB domestic demand, and there appear Miba Bearing Group at 32%. Miba Friction Group contributed to be few prospects of any rapid improvement.” approximately 23% to consolidated sales. Just under 8% Second quarter 2012 net sales were MSEK 1,808, down comes from the New Technologies Group started last year. 3% year on year. Demand conditions were better than in www.miba.com the corresponding period of the previous year in Asia and North America, but worse in Europe and South America. Operating income was MSEK 285 and income after tax For over 65 years, weÕve been buying and selling ferrous and non-ferrous powdered metals. was MSEK 202. Lower sales volumes and lower currency hedging earnings had a negative impact on income, while We've processed and sold thousands of tons of powdered aluminum, titanium, copper, iron, price increases and savings measures had a positive effect. steel, and precious metals at very competitive prices. If it has anything to do with recycling powder, Ace Iron can handle it. Höganäs sales by geographical region First half year results (1 January - 30 June 2012) disclosed net sales of MSEK 3,621, down 0.5% year on year. Operating Euro PM2012 Basel 16-19 SeptemberHall 4.1, 2012 Booth 12 income for this period was MSEK 567 and income after tax see us in Call Robert Lando to buy or sell powdered metal. was MSEK 405. “Against the background of the concerns and uncertainty PM2012 Yokohama 14-18 OctoberHall 2012A, Booth 3-13 Toll-free, USA 1-800-313-9672 prevailing on the markets, we are pleased with sales nearly see us in comparable to the previous year, adjusted for the excep- Outside USA / Canada, call 1-269-342-0183 tional deliveries to Hoeganaes Corporation (GKN) in 2011. Our operating margin and cash flow remain satisfactory, Or visit aceironandmetal.com despite a visibly negative currency effect.” “We are retaining a fairly high rate of investment in research and development. Extensive work on the market launch of electromagnetic applications continues, and we made promising advances in the powder for Metal Injection Moulding (MIM) segment in the quarter,” added Danielsson. PM Tooling System www.hoganas.com The EROWA PM tooling system is the standard interface of the press tools between the Net sales Second quarter Accumulated MSEK toolshop and the powder press machine. 2012 2011 2012 2011 Its unrivalled resetting time also enables 1403 Fourth St. • Kalamazoo MI USA • 49048 Europe 537 618 1,108 1,222 you to produce small series at a proﬁ t. Mailing: PO Box 2666 • Kalamazoo MI USA• 49003 America 557 627 1,128 1,173 Call toll-free, USA: 1-800-313-9672 Asia 714 624 1,385 1,244 Outside USA/Canada: 1-269-342-0183 www.erowa.com Total 1,808 1,869 3,621 3,639 Fax: 1-269-342-0185 Email: [email protected] Net sales for Höganäs by geographical region aceironandmetal.com 4 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd © 2012 Inovar Communications Ltd Autumn/Fall 2012 Powder Metallurgy Review 5 Industry News | contents | news | events | advertisers | contact | | contents | news | events | advertisers | contact |

workforce at the site to accommodate GKN reports increased profits for the increased production. In 2010, the first half of 2012 company announced it would create a further 50 jobs at the site by 2013, GKN plc, the global engineering GKN Sinter Metals increased sales but has already exceeded that goal by business that serves the automotive, in all regions, benefiting from strong adding more than 75 new jobs (as of aerospace and land systems markets, automotive production in North August 2012). has reported increased profit and sales America and new business wins GKN committed in December 2010 across the group. Sales were up 16% entering production. Organic sales for to invest $3.45 million to equip its to £3,459 million in the first half of GKN Sinter Metals increased by 13% 220,000 square-foot facility in Salem. 2012, compared to £2,988 million in the in North America and 3% in Europe. The company has since invested same period of 2011. Operating profit Strong growth was also achieved in $7.1 million and plans to invest an for the group in the first six months of India, Brazil and China. additional $4 million in the next year. 2012 increased 31% to £293 million, Overall, GKN Powder Metallurgy As part of the project, the company compared to £224 million in 2011. reported a trading profit of £47 million purchased compaction presses, “GKN has continued to make good (2011: £39 million). The negative sintering furnaces and automation for progress both in terms of financial impact of currency translation was £1 the furnaces and presses. performance and implementing our million. The divisional trading margin The Indiana Economic Development strategy to build a global market- was 10.1% (2011: 9.0%). Return on Corporation offered GKN Sinter Metals, leading business. First half trading average invested capital was 18.2% LLC up to $250,000 in conditional tax has seen sales increases and margin (2011: 15.7%), reflecting the improve- credits and up to $100,000 in training progression for each of our four ment in profitability. At 31 December grants based on the company’s job Divisions and our new acquisitions, 2011, return on average invested creation plans. “With its optimal loca- Stromag and Getrag Driveline capital was 16.7%. tion, expansive infrastructure and high Products, are performing well,” stated Increasing trends in industrial quality workforce, Indiana continues to Nigel Stein, Chief Executive GKN plc. and automotive markets to improve hit the mark with automotive compa- “We expect 2012 to be another good fuel efficiency and reduce emissions nies around the world,” stated Indiana’s year of progress for GKN and, in addi- continue to drive the demand for Lt. Gov. Becky Skillman. tion, we look forward to welcoming our products made by Powder Metallurgy, “Our plant has had a significant new acquisition, Volvo Aero, into GKN state GKN. During the period, around turnaround in the last four years, with when the transaction completes in the £80 million (annualised sales) of new our location in Salem as a tremendous next few months,” he added. programme business was awarded. asset in that process,” stated Paul The GKN Powder Metallurgy Cook, Director of Operations, Segment

division is one of the world’s largest II at GKN Sinter Metals. “The result manufacturers of sintered compo- Additional $4m of our investment is a successful, nents and comprises GKN Sinter investment in Indiana sustainable business that is positioned Metals and Hoeganaes. site expansion well to continue to grow and prosper GKN Powder Metallurgy sales in in Salem.” the first half of 2012 were £465 million GKN Sinter Metals, LLC, plans to (2011: £435 million), an increase of continue expansion of its Indiana site 7%. The negative impact of currency with a further investment of US$4m Expansion in China translation was £10 million. Organic over the next year. GKN Sinter Metals states that it is sales increased by £40 million (+9%). In a statement issued by the Indiana expanding capacity to meet increasing Hoeganaes increased the number Economic Development Corporation demand from global and domestic of tons of powder shipped by 8%. (IEDC), GKN also plans to increase the customers in China. New equipment has been installed in its plant in Danyang, Jiangsu Province, which will increase production capacity by 30%. The investment will see new presses, furnaces and induction hardening machines installed at the plant, all of which are said to be state- of-the-art equipment meeting GKN’s global standards. GKN Sinter Metals’ business in China has been growing significantly and is expected to double in the next few years. The plant manufactures Powder Metallurgy components for automotive powertrain applications. www.gkn.com This differential bearing adjuster manufactured by GKN Sinter Metals won the MPIF’s Grand Prize in 2011 (Photo courtesy MPIF)

compared with the corresponding Hitachi Chemicals states that first Nippon Piston Ring Co., Ltd. Japan’s PM industry reports good early period last year. Net income for the half sales to September 30, 2012 Nippon Piston Ring Co., Ltd., Japan’s 1st quarter decreased by 1.9% to Yen and fiscal year end March 31, 2013, leading producer of automotive engine growth in 2012 5,398 billion. are expected to exceed the forecasts parts such as piston rings, cylinder MMC’s ‘Advanced Materials & previously announced. The company liners, and valve train parts, including After the trauma which beset most Tools’ division, which includes the is forecasting half year sales of Yen structural PM parts and complex parts of Japan’s manufacturing industries production of cemented carbide tools 245,000 billion ($3.1 billion) by the end made by Metal Injection Moulding, due to the earthquake and tsunami in and structural PM parts, reported a of September 2013. reported full year results for 2011/2012 the north east of the country in March 1% increase in sales in the 1st quarter www.hitachi-chem.co.jp ,which saw sales rise by 3.7% to Yen 2011, most industry sectors, including to Yen 36.6 billion ($465 million) but a 49,168 billion ($624.9 million) in a powder metallurgy, have been able 27% drop in operating profit to Yen 3.2 turbulent market. to resolve problems and are back on billion ($4.066 million). Sales in the 1st quarter of the track for growth in 2012. Cemented carbide tools sales were Fine Sinter Co., Ltd. current financial year (2012/2013), The Japan Powder Metallurgy A sintered base valve seat used in shock negatively impacted in 2012 by the however, remained flat compared with Association (JPMA) reports that iron absorbers for automobiles from Fine Fine Sinter Co., Ltd., one of Japan’s flood damage at the company’s MMC the previous quarter at Yen 12,584 powder shipments for PM increased Sinter (JPMA 2011 award winning part, leading PM producers, reported that Carbide Tools facility in Thailand, billion ($159.8 million). to 46,499 tonnes in the first five image courtesy JPMA) year-on-year sales to March 31, 2012, which is undergoing repairs. shrank by around 3% to Yen 33.65 www.npr.co.jp months of the year, an increase of PM components used in a high response Capital expenditure by the This segment achieved 1st quarter billion ($424 million) but with net 13.5% compared with the same period VVT system produced by Sumitomo Advanced Materials & Tools division sales of Yen 55,209 billion ($701.5 income increasing by 67% to Yen 2.138 in 2011, which was affected by the Electric Group (JPMA 2011 award winning in 2012 jumped to Yen 11.4 billion, an million), an increase of 7.3% over the billion ($27.2 million). natural disaster from March 2011 part, image courtesy JPMA) increase of 98.7% over the amount st onward. However, copper powder same period in 2011/2012. For the 1 quarter (to end June spent the previous year. Sales of PM products were up 2012) the company stated that it had shipments for PM declined by 5.9% and demand for the Group’s automo- www.mmc.co.jp thanks to the recovery in car produc- achieved sales of Yen 9,097 billion to 2,047 tonnes also in the same five tive related products, which make up tion, and sales of friction materials ($115.5 million) with net income of month period. more than 50% of sales. Net income also recovered following the transfer Yen 473 million. Sales have continued The JPMA reported that production increased more than threefold to ipmd.net of production to new sites due to their upward trend over the past four of structural PM parts reached 47,082 Yen 13.9 billion ($176 million) for this For the latest news from Hitachi Chemicals Ltd. the closure of the original friction quarters following the disruption tonnes in the first five months of 2012 period. Hitachi Chemicals Ltd reported a materials operation located close to caused by the earthquake and tsunami the Powder Metallurgy – an increase of 17.5% over the same The ‘Industrial Materials & small (0.2%) decrease in 1st quarter the Fukushima Dai-ichi Nuclear Power in March 2011. industry visit www.ipmd.net. period in 2011, and that production of Others’ division is one of six business 2012/2013 group sales to Yen 117,981 Plant. www.fine-sinter.com PM bearings was up by 5% to 4,796 segments at Sumitomo Electric and billion ($1.499 billion) but a much tonnes. includes the production of cemented sharper decline (27%) in profits, carbides (hardmetals), PM parts, and which fell to Yen 6,782 billion ($86.176 PM companies show mixed the fully owned A.L.M.T. subsidiary million). The company states that Q1 results that produces W, Mo, heavy metal, this reflects the substantial damage thermal management materials, caused by the Great East Japan Earth- Japan’s leading PM companies ceramics, diamond tools and quake and tsunami and the repairs and conglomerates have, however, hardmetals. needed at production facilities. reported mixed results for the first The division, which makes up The ‘Advanced Components and quarter (April 1 to June 30) of the around 13% of group sales, reported Systems’ segment of Hitachi Chemi- financial year 2012/2013. 1st quarter sales up by 5.3% to Yen 69.1 cals includes Automotive Products A surge in global vehicle production billion ($877.8 million) with PM part (structural PM and MIM parts, PM has helped increase sales in a number sales flat at Yen 10.9 billion ($138.4 bearings, friction materials, and of companies, but the earthquake and million) compared with the same plastic moulded products), Energy tsunami in North East Japan in March period in 2011/2012. Hardmetal sales Storage Devices and Systems (vehicle 2011, and also the severe flooding in showed an increase of 6.9% to Yen 18.5 batteries, capacitors) and Electronic Thailand later that year, continues to billion ($235 million), and A.L.M.T. sales Components (printed wiring boards). impact others. were slightly down in the 1st quarter at Yen 9.7 billion ($123 million). global-sei.com Sumitomo Electric Group Japan’s Sumitomo Electric Group has seen a significant rebound from the devastating effect of the Great East Mitsubishi Materials Corp. (MMC) Japan Earthquake that effected sales Despite the gradual recovery from in the 2011/2012 financial year (April the Great East Japan Earthquake 2011 to end March 31, 2012). The and the robust recovery in demand group has reported a 19.4% increase for automobile related products, the in sales to Yen 527.2 billion ($6.699 drop in copper prices and stagnant billion) for the 1st quarter of the demand for semiconductor related current financial year (April 1 to June markets has seen Mitsubishi Mate- Hitachi Chemicals produce this light- 30, 2012). rials Corp. (MMC) 1st quarter net sales weight sinter diffusion bonded carrier used Growth was achieved on the back (April-June 2012) down by 12.4% to in a 4WD transmission (JPMA 2011 award of a global rise in vehicle production Yen 309,674 billion ($3.934 billion) winning part, image courtesy JPMA)

8 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd © 2012 Inovar Communications Ltd Autumn/Fall 2012 Powder Metallurgy Review 9 Industry News | contents | news | events | advertisers | contact | | contents | news | events | advertisers | contact | Press Technology at its best: Ceratizit invests in Günther Wirth synchronous compaction. The Ceratizit Group has announced end mills,” stated Jacques Lanners, that it plans to acquire a 50% share of representative of the Ceratizit Execu- German tool manufacturer Günther tive Board. In the future, GW will be Get ahead with the most advanced press technology for the modern P/M parts production: Wirth (GW). incorporated into the Ceratizit Group synchronous compaction. Synchronous pressing allows each column of powder to densify at the same Günther Wirth specialises in the as a global business unit, and will production of rotary cutting tools remain as a brand. rate, and reach the nal compaction position at precisely the same moment. The real closed loop controlled from hardmetal. The Wirth Group “The GW brand is superbly posi- compaction technology of multi level P/M parts – the compaction technology without mechanical stops. was founded in 1981, and besides the tioned in the case of end users and parent plant in Swabian Balzheim, dealers - in Europe and in the USA Jacques Lanners (left) representative Germany, includes production sites and India. As a part of the Ceratizit of the Ceratizit Executive Board and GW in France, India, the USA and Italy. Group we want to develop this offering founder Mr Günther Wirth (right) The family owned company employs worldwide”, stated company founder around 500 people and is one of the Günther Wirth. Ceratizit and GW have of 2012. Ceratizit and the current leading manufacturers of rotating worked closely together for many shareholders around the company’s cutting tools such as drills, end mills, years and have already cooperated founder Wirth will each hold 50% of reamers and rods. in the manufacture of blanks and the GW company after the transaction “With this acquisition, we will be finished tools. is finalised. Both private companies able to cover the whole value chain in The transaction is expected to be have agreed not to disclose any hardmetal production - from powder, completed, subject to the finalisation financial details. to tool blanks to custom-made and of due diligence and approval by the www.ceratizit.com coated round tools such as drills and anti-trust authorities, by the end www.gw-tools.de

Hitachi Chemical H.C. Starck and Jiangxi Rare Earth & Rare expands its PM Metals Tungsten Group Holding expand production in tungsten business in China

China H.C. Starck and Jiangxi Rare Metals eration between Chinese and German Tungsten Group Holding Co. Ltd. high-tech companies,” stated Zhong The Chinese subsidiary of Hitachi (JXTC), one of China’s largest tungsten Xiaoyun, President and CEO of JXTC. Chemical Co., Ltd., Hitachi Powdered mine operators, have celebrated the The previous preparatory work for Metals (Dongguan) Co., Ltd. (HPMD), ground breaking ceremony for their the joint venture has been strongly is to expand production capacity tungsten joint venture in Ganzhou City, supported by government authori- through construction of a new factory Jiangxi Province, China. Scheduled ties. “We are convinced that the joint at its existing site in Guangdong. to start operations in late 2013, the venture will contribute to resource The Chinese auto market is new plant will produce tungsten metal preserving and sustainable develop- expected to grow by 10% per annum, powders and carbides exclusively for ment of the Chinese tungsten industry states the company, and the new the Chinese market. and, as a result, will be a business facility is in direct response to the “This joint venture is our largest success for all parties involved,” increased demand from this market. project to date in China and the core explained both Zhong and Meier. “The Production is planned to commence at of our growth strategy in Asia. I am joint venture will also strengthen H.C. the new factory in autumn 2012. pleased that we could win an experi- Starck’s raw material supply chain. HPMD manufactures Powder enced and reliable partner like JXTC And the facility will create about Metallurgy products for the Hitachi for this project,” stated Andreas Meier, 400 new jobs which will boost the Chemical Group and has technical President and CEO of the H.C. Starck economic and social development of expertise in the automobile and Group. “We will primarily supply Jiangxi Province.” construction machinery sectors. the products of our joint venture to Ganzhou is one of the largest cities In addition to products currently the hard metal manufacturers for in the province of Jiangxi, which has manufactured at the site, the produc- the automotive and engineering large natural-tungsten deposits. tion of sintered bearings, which are industries as well as to suppliers for Advanced tungsten products are used seeing increasing demand in China, is the mining and energy industry in as high performance materials in a With more than 140 years of experience and know-how, LAUFFER to commence. China,” he added. “Demand for higher variety of growth industries, including PRESSEN has established itself as a specialist in the eld of hydraulic Hitachi Chemical Group has quality tungsten products continues speciality cutting tool manufacturing, presses. With our strong commitment to product- and process inno- powder metal product manufacturing to increase in China. With our joint wear parts for mining, tunnel and read vation, quality and customer service, we are your partner for powder locations in Japan, China, the US, venture, we will be able to serve this construction, as an alloy metal, and compacting and sizing presses. For more information about LAUFFER, Singapore, Thailand, Indonesia and market over the long term.” for components in the aerospace and India (to commence operation in April “This cooperation plays to the medical engineering industry. please visit us at: 2013). competitive strengths of both partners www.hcstarck.com www.hitachi-chem.co.jp and creates a new model of close coop- www.jxtc.com.cn www.lau er.de Forming your ideas

Novomet utilises Pittman Motors PM and Laser uses range of PM Sintering for components in submersible new planetary centrifugal pump gearbox

parts Pittman Motors, part of the AMETEK Precision Motion Control division, has Novomet, based in Perm, Russia, introduced a new compact planetary claims to be the country’s largest gearbox as an addition to their exten- producer of electric submersible Electric submersible pump produced by sive line of DC motor and gearmotor pumps (ESPs) used in harsh oil and Novomet as part of downhole ESP system products. gas well conditions including high gas The G30A planetary gearbox incor- required to have high corrosion to oil ratios, heavy oils, high tempera- porates sintered steel planet gears resistance. tures, and in abrasive and corrosive to promote high torque capacity and In addition the PM stainless steel fluids. low audible noise while maintaining a grades are required to have high abra- The company, which was estab- compact design. sion resistance in the harsh operating lished in 1991 and currently employs Single piece carrier plates with conditions. The company also produces around 4,000 people worldwide, integral gear posts and sun gear can PM abrasion resistant radial and axial uses patented technology to produce be arranged to achieve many different bearings for its centrifugal pumps. The complex shaped PM stainless steel reduction ratios. bearings are made from a tungsten components for the demanding appli- The gearbox output is through carbide base material, which is said to cations in ESPs. The stainless steel a 416 stainless steel shaft and a have improved plastic characteristics powder grades are used to produce sintered metal output bearing. and resistance to vibration and impact the pressed and sintered stage pump The G30A gearbox is a perfect loads. parts with complex shapes and internal complement to the Pittman brush Novomet has installed a SLS cavities for submersible centrifugal and brushless DC motors, states the (Selective Laser Sintering) system for pumps used in oil production. company. When the G30A is combined the production of 3-D prototype parts The pumps have been specially with the latest motor materials and from powdered materials for evaluation developed for operation in reservoir manufacturing technology such as in ESPs and other applications. fluids such as hydrochloric acid and high energy neodymium magnets, www.novomet.ru hydrogen sulphide and are therefore silicon lamination steel, and advanced winding techniques to maximise slot fill, a high efficiency system is created perfectly suited for high-tech motion New upgrade for Global Powder applications. Pittman also offers a wide variety Metallurgy Property Database of complementary products such as gearboxes, encoders, brakes, and The ground-breaking online Global Metal Powder Industries Federation drive systems. Powder Metallurgy Property Database (MPIF) and the Japan Powder Metal- www.pittman-motors.com (GPMD) was launched in 2004 as a lurgy Association (JPMA). joint project between the world’s three Since its launch, the database has leading regional PM trade associa- been refined and extended to include tions, the European Powder Metallurgy the non-ferrous PM and MIM sectors Association (EPMA), North America’s with coverage of nearly 4000 lines of Fine Sinter to high quality data. establish new PM In the latest development, additional information covering recently plant in Indonesia introduced hybrid ferrous structural grades, based on the sinter-hardening Fine Sinter Co. Ltd., one of Japan’s material, FL-5108, and the diffusion- leading PM producers, has reported alloyed material, FD-0105 has been that it is establishing a new manufac- added. turing subsidiary in Indonesia. The data is displayed in a user- The new PM plant will start opera- friendly interface viewable in both tions in January 2013 with an expected tabular and graphic formats and it is workforce of around 110 people. hoped it will be of particular interest Currently the company has five to design engineers in a range of manufacturing subsidiaries in Japan, An example of the data that can be industries. Thailand, North America and China. extracted from the Global PM Database www.pmdatabase.com www.fine-sinter.com

MaterialsScience temperatures, hydrogen nuclei not only in the resilient materials themselves, but also in the ITER nuclear fusion heat exchanger possess sufficient kinetic energy joining technology used within the composite. to collide with each other despite Once the fusion plant has been taken into operation, set for series production using the repulsive electric force between any repairs represent a huge outlay in terms of time and Plansee expertise them, and fuse to form helium nuclei. money. Any downtime of the plant, no matter how short, is an Recoverable energy is released during expensive exercise. Only a perfect joint between the armour this nuclear fusion process. and the heat sink prevents overheating and damage to the It’s possible to generate power in of what can be achieved with today’s A magnetic field encloses the hot divertor. Plansee has developed and patented its own joining an environmentally compatible and technology. plasma in order to maintain the fusion process specifically for the nuclear fusion industry: “active Acrawax™ C sustainable way using nuclear fusion. Test scale components from process and to protect the components metal casting”. This method ensures that heat is transmitted This, states Plansee SE, based in Plansee have already proved them- of the plant as much as possible. to the heat sink extremely efficiently and reliably. Reutte, Austria, is what the interna- selves and have made a significant Only very few components come into Over the course of the coming months, the team from tional research project ITER (Interna- contribution to the reference design of contact with the outer regions of Plansee will be working together with a large number tional Thermonuclear Experimental the forthcoming ITER plant. Plansee the plasma. One area that becomes of engineers and production staff to construct the first Reactor) has set out to prove by 2030 was recently awarded the contract for particularly hot is the divertor. full-scale partial segments of the divertor for ITER. All the at the latest. manufacturing full-scale prototypes. At particular points in the magnetic individual steps in production must be perfectly coordinated Only components that meet the This final stage before series manu- field, generally near the bottom of the and technically harmonised. most stringent technical requirements facturing is a serious challenge, and plasma vessel, the helium ions and Joining some 130 armour blocks to the backing tubes can be considered for use in the ITER only three companies worldwide were impurities in the plasma are guided of the heat sink in a single step without the slightest error system. Above all, the heat exchangers able to qualify. towards the divertor. There, the ions is just one of the many challenges to be overcome during of the diverter are subject to extreme are slowed down and electrically the project. Traditional quality assurance measures are not temperatures. How does nuclear fusion work? neutralised. In order to prevent the appropriate to the complexity of this development task. In Plansee states that is has recently Energy is released when hydrogen divertor components from melting or order to be absolutely certain, Plansee has developed its own reached the final qualification phase nuclei fuse to form helium nuclei. even vapourising, the heat that has non-destructive testing methods for ITER based on thermo- prior to series manufacture with its That is the simple recipe for success been generated must be removed as graphic and ultrasound techniques. components and is now looking to behind this environmentally friendly quickly as possible. Stress testing on all ITER prototypes should be completed become established as one of the key and sustainable source of energy. The If the divertor is unable to withstand successfully by mid 2014. Series production of the ITER suppliers to ITER. shining example of this process is the extreme stress, the continuous components can then start. the sun, which also generates energy operation of the fusion plant is simply www.plansee.com International cooperation using the same principle. But although not possible. As a result, only compos- Seven nations are currently working it may sound simple, it is in fact the ites that can withstand an extremely together on building a nuclear fusion result of the complex interplay of many high level of generated heat of up to plant as part of ITER, the world’s most factors. 20 MW/m² and are capable of resisting extensive fusion experiment. For the In the nuclear fusion plant, the ceaseless attack of electrons, ions Record profits for Sandvik in first time, the plant is intended to hydrogen gas will be heated to and impurities are used in the divertor. deliver more power than is required temperatures in excess of 100 In principle, the divertor is made first half of 2012 for generating and maintaining the million °C. This produces a plasma up of a highly efficient heat sink for Operating profits for Sandvik AB in the first half of 2012 plasma. Some of the requirements in which the electrons are separated dissipating the heat protected by an amounted to 8,031 million SEK (6,834 million SEK in 2011), the on the components stretch the limits from the nuclei. At these extreme armour. The armour protects the heat Metal Powder Lubricants sink from being damaged by the hot highest level recorded to date. plasma during operating conditions. The operating margin was 15.8% (15.0) of invoiced sales – High Performance in the period January - June 2012. Changed exchange rates – Clean Burning Material choice had a positive impact of 250 million SEK on earnings during the first half of the year, compared with a year earlier, while Tungsten and carbon are the materials changed metal prices had a negative impact of 118 million Acrawax™ C ethylene bis-stearamide has been the of choice for this armour. These mate- SEK. benchmark for excellence in the metal powder industry rials are particularly heat resistant and Order intake increased to 55,084 million SEK (50,262) up for almost fifty years. Acrawax™ C provides excellent free dissipate heat very efficiently. Unlike 10% in total and 7% in fixed exchange rates for comparable flowing powder mixes, easy part removal from the die, carbon, tungsten does not bind a large units. Invoiced sales were 50,776 million SEK (45,451), up low die wear, and reduced part distortion. Acrawax™ C amount of hydrogen and has a low 12% in total and 9% in fixed exchange rates for comparable interaction with the plasma resulting units. is available in a variety of custom particle sizes for the in lower impurity levels of the plasma. Sandvik stated that the global market demand improved metal powder industry. It also provides excellent green This makes tungsten a particularly during the first half of the year compared with the first six and sintered properties. Since Acrawax™ C is 100% metal- suitable material in highly loaded months of 2011, although uncertainty increased towards the free, it is completely combustible and leaves no residue areas of the first wall of nuclear fusion end of the period. on sintered parts. This clean burning lubricant generates plants. The improvement was most tangible for Sandvik Mining no metallic or corrosive by-products which can contrib- As a leading expert for refractory and North America in general. metals, Plansee manufactures armour www.sandvik.com ute to environmental emissions and furnace corrosion. The current reference design for the high-performance heat exchangers for the ITER composites for the divertor made from divertor involves monoblocks manufactured from tungsten and carbon fibre reinforced carbon fibre reinforced carbon (CFC) graphite (CFC) that are joined to a CuCrZr alloy tube using a patented joining technology. and tungsten monoblocks and joins For the latest news from the PM industry, Lonza Inc., 90 Boroline Road The channel sections on the bottom are manufactured from special steel and are the armour to the copper/chromium/ register for our free e-newsletter at Allendale, NJ 07401 intended to be used later for connecting the assembly to the support structure of the ITER zirconium-based heat sinks. Plansee www.ipmd.net/enews Tel 800 777 1875, Fax 201 785 9973 divertor. The figure shows a prototype having approximately 25% of the final overall length states that its particular expertise lies [email protected] www.lonza.com

Höganäs turns to HIP technology for high performance PM gears for rally cars

In 2011 Swedish iron powder producer further proof that the sintered gears Höganäs AB and SwePart Transmis- work really well. As this was a rather sion replaced the 4th set of gears in challenging racing track, it was a Ramona Karlsson’s rally car with perfect opportunity for us to verify Powder Metallurgy gears. After proving the performance ahead of the WRC that Powder Metallurgy gears could competition in New Zealand in June,” match the performance of the original stated Ramona. This EVO X contains PM gears that have steel gears, the next step was to Since a rally car’s gear box typically been manufactured using HIP replace the remaining gears to create is replaced two to three times during a complete PM transmission solution. a World Rally Championship (WRC) that had not been HIPed performs in season, Höganäs has now developed The future successracing for PM technology conditions is to be found in thein close comparison interaction between application to a knowledge, design aspects, optimum process conditions and high-quality powder materials. Based on this Ramona Rally team races in a five complete gear boxes together withnotion we openedsteel the door gear. to our PoP Centre. Mitsubishi EVO X during the 2012 SwePart Transmission. One example of howA we extendMitsubishi the market for PM technologyEVO8 in thewith PoP Centre, perfor is high load-carrying- PM season On August 24-26, 2012, the gears. We have already proven the concept and now advance our development activities even further. Join us in themance development of newsimilar powder based to applications. a typical rally car In 2012 the Ramona Rally team German town of Trier hosted a WRC has been used for the test and the races in a new car, a Mitsubishi EVO competition. For this race Höganäs goal is to run 1,000 km. Up until now X, with a new transmission housing arranged a special event including the car has been driven for more manufactured by Australian company the opportunity to experience live rally than 600 km with good results and no Pfitzner Performance Gearboxes (PPG) and to watch Ramona and PM gears gear damages have been found after and containing PM gears that have in action. inspection. been manufactured using Hot Isostatic To watch Ramona and her co-driver ® Pressing (HIP). No HIP with Hipaloy Miriam in action, visit the official During a recent rally competition Ramona has also been involved in website: www.ramonarallying.com in Karlskrona, Sweden, the Ramona the testing of gears manufactured Höganäs also reported that the Rally team had another opportunity to from Höganäs’ Hipaloy® material. By Smartcar with its gearbox containing test drive the sintered gears, and once analysing reports on gear shifting PM gears had reached 100,000 km again reported good results. under full throttle, the intention has with no problems. “It went very well and we got been to investigate how a PM gear www.hoganas.com

Hagen Symposium to focus on PM raw ESPG launches new materials and future application trends projects

The Hagen Symposium on Powder In addition to the Skaupy presenta- The European Structural Parts Group Metallurgy, organised by the Ausschuss tion by Dr Sigl, which will focus on (ESPG) is one of the sectoral working für Pulvermetallurgie, is a key annual innovations in PM technology for the groups of the European Powder event in the German-speaking energy sector, there will be presenta- Metallurgy Association (EPMA). countries of Europe and brings together tions on the use of ceramic membranes The ESPG recently launched a new more than 250 delegates from industry, in ‘Carbon Capture and Storage (CCS) club project on ‘Component Fatigue research, and academia over a two day in coal fired power plants (M. Schröder, Strength (Phase 1) in partnership with period to review trends in PM tech- Inst. For Physical Chemistry, TU RTWH IPAK Aachen, which has the nology and its products. Aachen), and the production of PM objective to predict the fatigue strength The 31st Hagen Symposium will metal and metal-ceramic composites at constant stress ratio R of a PM take place as usual at the Town Hall in for power plant membranes (H.-P. component by a material master curve Hagen, November 29-30, 2012, and in Buchkremer, Forschungszentrum for three ferrous PM alloys. addition to a full technical programme Jülich). The viability of the method will be will feature more than 50 exhibitors. The 31st Hagen Symposium will demonstrated using a PM injector The Skaupy Prize for 2012 will be conclude with hard material related clamp for common rail systems presented to Dr Lorenz Sigl, Director presentations covering new develop- produced by AMES, which is supporting of Research at Plansee SE, Reutte, ments in coatings for cutting tools, new the project financially along with GKN Austria. concepts for diamond tools, and the Sinter Metals, MIBA, and PMG Füssen. The organisers state that the key impact of availability of tungsten raw The EPMA reports that final results objective of the 2012 Symposium will be material on the hard metal sector. and Roadmap for possible next stages to review trends in a wide range of PM www.pulvermetallurgie.com for this project should be made avail- industry sectors, including ferrous and able in October 2012. non-ferrous powder developments. www.epma.com Thermal Technology’s model HP500-242424G

Toshiba develops dysprosium-free Plansee Group samarium-cobalt magnet to replace reports sales of heat-resistant neodymium magnet in more than Euro 1.5 essential applications billion

Toshiba Corporation has announced neodymium magnet. The high-iron The Plansee Group has announced the development of a high-iron concentration samarium-cobalt sales of more than €1.5 billion in the concentration samarium-cobalt magnet exceeds the heat-resistant last fiscal year. “Despite the global magnet that is free of dysprosium, a neodymium magnet in magnetic force uncertainties caused by government rare earth mineral that is in extremely by 1% at an operating temperature of debts, Euro and banking crisis we short supply and increasingly 100°C and by 5% at 150°C. were able to successfully continue our expensive. Toshiba achieved this by reducing worldwide expansion during 2011,” At typical operating temperatures, the oxide and the phase with high Plansee Group’s Executive Chairman, the samarium-cobalt magnet has copper concentrations in the magnet, Dr. Michael Schwarzkopf, stated at the superior magnetic properties to the both of which inhibit magnetic force, annual press conference in Reutte. heat-resistant neodymium magnets and by increasing the amount of iron Consolidated Group sales increased currently used in motors. in the magnet from 15% to 20% by by 22% in the last fiscal year (ended The traction motors for hybrid weight. February 29, 2012) to reach €1.52 and electric automobiles, railroad Toshiba has verified the perfor- billion. According to Schwarzkopf, vehicles and the motors for industrial mance of the new magnet when “Business developed satisfactorily equipment operate at relatively high applied in motors for automobiles, in all divisions and in all important temperatures, and heat-resistant locomotives, machine tools and eleva- regions for Plansee. Increased sales neodymium magnets are generally tors, confirming that it has almost the volumes and raw material prices, used in these applications. Dysprosium same capabilities as heat-resistant acquisitions and changes within is a key material of these magnets, neodymium magnets of the same the group portfolio had a significant but current sources of dysprosium are size. The magnet is highly suited to impact on sales growth.” limited. motors that must combine high heat At the regional level, the Plansee Recent export limitations and price resistance with high performance and Group benefited from the robust rises are raising global concerns for a small size. US economy and Germany’s export future shortages and the development The company aims to start mass strength. Strong growth was also of dysprosium-free high performance production of the magnet at the end of achieved in China and India. Sales magnets that offer a strong magnetic the current fiscal year and promote its outside of Europe slightly increased force at high operating temperatures is use in all applicable equipment. to 52% of the Group total (America an important objective for industry. Development of the magnet and 32%, Asia 20% and Europe 48%). More Toshiba states that it has used motor was supported by Japan’s New than half of Group sales were achieved heat-treatment technology to improve Energy and Industrial Technology in three market sectors mechanical the magnetic force of the samarium- Development Organisation’s (NEDO) engineering, automotive and consumer cobalt magnet, and in doing so has Rare Metal Substitute Materials electronics. boosted its performance to a level Development Project. surpassing that of the heat-resistant www.toshiba.co.jp Focus on high-technology materials molybdenum and tungsten With the acquisition of a 10% share in the Chilean company Molibdenos Metal prices soften on declining y Metales (Molymet) in March of last demand year and the sale of the sintered parts manufacturer PMG at the end of 2011, Some of the key metals used in the tungsten APT export prices have the Plansee Group is now focused on production of Powder Metallurgy declined from just under $410/mtu at the two key-materials molybdenum products such as structural parts, the start of 2012 to a range between and tungsten. “We will continue self-lubricating bearings, and $370 and $375 in mid-August. WC expanding our global market position hardmetal tools, have seen marked powder (3-4 microns) FOB P.R.C. fell in this business field,” explained downward slides over the first half of below $45/lb in August from around Schwarzkopf. 2012 mainly as a result of declining $55/lb at the beginning of the year. Due to the sale of PMG, which demand and the resulting oversupply LME copper, which has dropped employed 1,150 people worldwide, and build up of stocks. more than 27% from a record $10,190/ the Group’s workforce was down from For example, tungsten production ton in February 2011, has been stuck 6,730 to 6,120 employees at year-end. in China increased by a reported 16% in a narrow trading range between A new plant of the Plansee High to 57,585 tons in the first half of 2012, $7,300 and $7,600/t since July 2012. Performance Materials division is but with the global market largely Nickel has also moved downwards scheduled to come on stream in expected to stay weak there is poten- from $11/lb in August 2011 to less Shanghai in late 2012. tially an oversupply situation. Chinese than $7/lb in August 2012. www.plansee.com

New 648 page PM directory includes International Powder Metallurgy Market report highlights the resurgence essential technology reviews Directory 2012-2013 of the global PM industry 15th Edition www.ipmd.net th The 15 Edition of the International Powder Metallurgy Directory, 2012- “Powder Metallurgy: A Global Market Review” presents a detailed analysis 2013, was published by Inovar Communications Ltd earlier this year. of the current status of the global Powder Metallurgy (PM) industry. This 648 page publication contains essential PM market and technology Included in the 15th Edition International Powder Metallurgy Directory, or information, as well as a comprehensive directory of companies active in the available to purchase as a separate PDF download, the review provides PM industry worldwide. essential market data on the global PM industry.

Powder Metallurgy’s leading METAL & ALLOY POWDERS From Ore To Powder, reference source for 35 years To Meet Your Requirements! Powder Metallurgy: A Global Market volume growth in existing applications, Metal Powders • Iron and steel (including stainless) www.qmp-powders.com The International Powder Metallurgy Review, presents a detailed analysis of but thanks to continuing technological • Non-ferrous Directory (IPMD) is an essential refer- the current status of the global Powder innovations that are helping to push the • Refractory metals ence publication for anyone involved in Metallurgy (PM) industry. The report’s boundaries of how and where PM can • Carbide and ceramic the global PM industry. The directory author, Bernard Williams, formerly be used. From new high performance • Magnetic not only contains details of nearly 4800 Executive Director of the European automotive gears to complex compo- • Ultrafine/nanocrystalline companies involved in PM, but also Powder Metallurgy Association, nents for hybrid vehicles and fuel • Hardfacing includes more than 190 pages of PM presents extensive data on how the PM cells, the technology is proving to be • Pressing lubricants market and technology information. industry has witnessed a resurgence invaluable for the development of the th The 15th Edition IPMD is the most Trade associations, research The 648 page 15 Edition International in fortunes since the financial crisis of next generation of green vehicles.” comprehensive guide ever published centres, universities and consultants Powder Metallurgy Directory, 2012-2013 2008. Powder Metallurgy – A Global Market to both PM component producers and are also included. Published by Inovar Communica- Review, also features an inset review industry suppliers worldwide. Purchase information tions Ltd, the report also presents data of the current status of Metal Injection On-line database access included The International Powder Metallurgy on the emergence of China and other Moulding (MIM) and Ceramic Injection What does the directory cover? All purchasers receive 12 months Directory 15th Edition is published by Asian countries as the leading global Moulding (CIM). Collectively known as The IPMD directory lists not only access to the on-line IPMD database, Inovar Communications Ltd. ISBN region for the manufacture of powder Powder Injection Moulding (PIM), this Powder Metallurgy industry suppliers, searchable via the www.ipmd.net 978-0-9558223-2-2. The publication is metallurgy products. technology has enjoyed dramatic growth but also all known Powder Metallurgy website. A4, soft cover, 648 pages. Price: £195 The review covers all aspects of PM over recent decades and is estimated to parts and product producers. Some 200 including airmail shipping worldwide. production, including structural compo- have reached record global sales of $1.2 product codes are used to identify each www.ipmd.net nents, high alloy PM steels, copper and billion in 2011. company’s specific area of activity. copper-base products, hardmetals/ “The PIM industry has shown itself The IPMD is an indispensable tool for those involved in PM, for end-users Detailed PM market and technology information and industry analysts. Listed below are “The global PM industry regained its growth In addition to the fully revised and • PM Superalloys for High the main product categories included in updated “Powder Metallurgy: A Temperature, High Perfor- the IPMD: momentum in 2010 and 2011 after the Global Market Review” (see facing mance Applications page), the IPMD contains essential turbulence caused by the financial crisis of PM PRODUCTS • PM Fully Dense High Alloy information on all aspects of PM Steels 2008. Ferrous PM part production was set to • Sintered structural parts technology and applications. Features • An Introduction to Powder which includes some 25 tables and 35 • MIM / CIM in the 15th Edition IPMD include: Metallurgy Soft Magnets break through the one million tonnes barrier figures, costs £145 and is available to • Special PM alloys download in PDF format from www. • Powder Metallurgy Permanent • Magnetic/electrical parts PM PARTS & PRODUCTS in 2011 and the prospects for 2012 remain ipmd.net/marketreview. The review is Magnets and their Applications • Cemented carbides very positive” also available in print as part of the • Diamond tools • Developments in the Production • PM Self-Lubricating Bearings new 15th Edition International Powder • Heavy metals of Structural PM Components Continue to Make Advances Metallurgy Directory 2012-2013. • Friction materials • High Density, High Performance cemented carbides, diamond tools, to be capable of significant annual • Bearings Powder Metallurgy Components PM MATERIALS & PROCESSING refractory metals, and powder-based growth, which has averaged 13% About Inovar Communications Ltd • Sintered filters • International Award Winning • Trends and Innovations in magnets. Powder metallurgy’s special per annum over the past 10 years,” Inovar Communications Ltd, based • Foam structures Parts Powder Compaction Presses relationship with the automotive commented Williams. “This high in the UK, is a specialist technical industry is also addressed. growth rate is expected to continue in publishing company dedicated to the • Metal Injection Moulding (MIM): and Die Sets PRODUCTION EQUIPMENT “The global PM industry regained its the years ahead with some forecasts Powder Metallurgy (PM) and Powder Materials, Processes and • Sintering Equipment and growth momentum in 2010 and 2011 predicting Asia to double sales from Injection Moulding (PIM) industries. • Powder production Applications Atmospheres used in Powder • Mixing and milling after the turbulence caused by the 2009 levels by 2014. North America As well publishing Powder Metallurgy • Complex shaped metal powder Metallurgy • Powder presses financial crisis of 2008 and the ensuing is forecast to achieve sales of around Review, the company’s portfolio of components made by Additive • Trends in Ferrous Powders for • Compacting tools economic recession. Ferrous PM part $425 million in the same timeframe. publications includes Powder Injec- Manufacturing use in Powder Metallurgy • Sintering furnaces production was set to break through Europe is expected to have the lowest tion Moulding International, ipmd. • Atmospheres/generators • Innovations in Tungsten Carbide- • Non-Ferrous Powder Produc- the one million tonnes barrier in 2011 annual regional growth rate but still at net - the premier on-line resource • Finishing Cobalt Hardmetal Technology tion Technologies and the prospects for 2012 remain very a healthy 11.6%. This will take global for the PM industry, the weekly ipmd. • Processes/coatings • Production and Applications of • Trends in Nano Powder Produc- positive,” stated Williams. MIM sales close to the $2 billion mark net e-newsletter and the International • Automation PM Diamond Tools tion and Applications “The Powder Metallurgy industry is by 2015.” Powder Metallurgy Directory. • Testing and analysis on a positive footing not only because of The 12,500 word market review, www.ipmd.net.

Recent trends in Hot Isostatic Pressing (HIP): Processing and applications

The processing of primarily large Powder Metallurgy (PM) near-net shapes such as superalloys, tool steels, stainless steels, and titanium by Hot Isostatic Pressing (HIP) has been used extensively since 1970 and an estimated 1000 HIP systems* have been installed since that time. HIP systems are also used for defect healing of castings, diffusion bonding and cladding, and fully densifying hardmetals (cemented carbides). Bernard Williams looks at trends in HIP process technology and applications for powder materials.

Hot Isostatic Pressing (HIP) involves bonding across the interface due to the HIP systems the simultaneous application of high diffusion of atoms in both directions. pressure (15,000 to 45,000 psi) and The closure of internal porosity A HIP system requires a pressure elevated temperature (up to 2500°C) in castings by HIP without affecting vessel, inert fluid (gas), means of pres- in a specially constructed vessel. the microstructure has considerable surising the fluid (gas), and a heating The pressure is usually applied with benefits in improving the reliability of a system. The original hot isostatic an inert gas such as argon, and so casting, particularly when the castings press used a monolithic forged steel is ‘isostatic’. Under these conditions are used in the aerospace, medical, autoclave sealed by a threaded top of heat and pressure internal pores automotive, offshore and marine closure through which the inert gas, or defects within a solid metal body sectors, stated Dr Davies. argon, was pumped. The requirements collapse and diffusion bonding occurs at the interfaces. Encapsulated powder and sintered components can also ipmd.net be fully densified to give improved mechanical properties and a reduction in the scatter band of properties. In Your on-line source for PM industry some cases, such as large powder metallurgy semi-products or large near-net shape PM components news, technology and more.... weighing several tonnes, HIPing is the only viable manufacturing option. In a recent presentation Susan Davies, General Manager of Bodycote Sign up for our FREE weekly PM e-newsletter HIP Ltd in the UK [1], stated that HIP conditions are generally chosen so that the gas pressure at a specific today at www.ipmd.net/enews temperature exceeds the yield stress of the material at that temperature. Under these conditions plastic flow occurs on a microscopic scale allowing the formation of isolated pores, which then collapse to allow direct contact of the two surfaces. This in turn allows

EURO PM2012 PM2012 Yokohama *Around 50% of these HIP installations were Fig. 1 A large hot isostatic press with a working diameter of 1.62m and height of 2.33m for R&D applications. (Courtesy Avure Technologies) Scan the QR code to visit www.ipmd.net Stand #39 Stand #2-16 22 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd © 2012 Inovar Communications Ltd Autumn/Fall 2012 Powder Metallurgy Review 23 HIP technology | contents | news | events | advertisers | contact | | contents | news | events | advertisers | contact | How do you make parts stronger?

With post-sinter hot isostatic pressing, not only do you get stronger PM and PIM parts, but now the Fig. 2 Hot isostatic presses with hot zone Fig. 4 Layout of the world’s largest HIP system installed at Metals Technology Ltd in diameter up to 1650 mm are built by Japan to densify large castings and to produce PM parts for the aerospace, electronics process is more efficient and cost effective than ever EPSI Inc. and petroleum industries. The HIP system was produced by Avure Technologies, Sweden with Uniform Rapid Cooling from Avure Technologies. forces are transferred through the two in cycle time reduction due to rapid moving closures to the external frame, cooling, has made the use of HIP Maximum density for superior strength and durability which is also pre-stressed with the as a powder consolidation process ü wire winding. Pressure is sealed within considerably cheaper in general terms ü Zero internal porosity means less machining and better the vessel using Bridgman seals, than it was 20 years ago. An example surface finish metal-to-metal seals, single or double of HIP process cost reduction is given ü Exclusive Uniform Rapid Cooling for fast, economical batch Medium to large HIPs are designed per processing customers’ requirements, with available “the next generation of HIP equipment capacities of thousands of pounds per cycle will have working diameters of at least Uniform Rapid Cooling reduces cycle times by up to 70%, 3 meters and over 5 meters in height” dramatically cutting the per-unit cost of HIPing PM and PIM parts. Up to three cycles can be completed in a single 8-hour shift. O-rings, or a combination of these. in Fig. 5 [3]. The data in the figure The pre-stressing causes the pres- assumes a HIP pressure of 1050 bar, ü Improved tensile strength sure vessel wall to remain in residual and includes labour costs, utility and Maximum hardness compression even at maximum maintenance costs, and a five shift ü operating temperature, eliminating operation for 300 days/year. ü Greater corrosion resistance tensile loads, and preventing crack ü Minimal grain growth and distortion. propagation and brittle failure. Such a The heart of the HIP Fig. 3 The pressure vessel is the backbone vessel has a calculated fatigue life of system of any HIP system. (From presentation more than 20,000 cycles [2]. Compact models, ideally suited to PIM, for up to 55 lbs. per cycle by A. Eklund, Avure Technologies, at Fig. 4 shows the layout of the Avure Technologies believes that if ‘Workshop on HIP Processing of Materials world’s largest ‘giga-HIP’ system the isostatic pressure vessel is the for Aggressive Environments’, Derby, UK, built by Avure Technologies (Sweden) backbone of a HIP system, then the November 16, 2011) and installed at Metals Technology furnace is the heart (Fig. 6). The furnace Ltd in Japan in February 2010. The consists of resistance heater elements for ever higher pressures and/or system has a 2050 mm inside working arranged in multiple, independently temperatures has seen the develop- diameter by 4200 mm tall, which controlled zones. The choice of furnace Download a FREE white paper now at ment of new designs of HIP systems can process parts at temperatures and heater element materials will including multi-wall forged, relatively up to 1350°C and pressures of 1180 depend on the material being HIPed thin-walled vessels surrounded by bar (17,000 psi). Avure Technologies and the temperature. For temperatures www.avure.com/pim tight fitting forged steel rings, or steel believes that the next generation of up to 1350°C Fe-Cr-Al alloys (Kanthal) wire wound. Two examples of commer- HIP equipment will have working can be used as heater elements. Molyb- The white paper describes current and future cial HIP equipment are shown in Fig. 1 diameters of at least three meters and denum can be used in the temperature and Fig. 2. over five meters in height, and there range 500 – 1600°C, and graphite for trends in hot isostatic pressing. You’ll also In the steel wire wound system, are preliminary designs that would temperatures from 400 to 2200°C or receive a data sheet on uniform rapid cooling. for example, the radial forces are allow a 4000 mm working hot zone higher. Graphite has the advantage of taken up by a forged steel cylinder diameter. lower cost than refractory metals and pre-stressed with kilometers of high The availability of such large HIP has good strength and dimensional strength steel wire (Fig. 3). The axial systems and the associated advances stability at high temperatures.

HIP ø HIP ø Graphite furnaces are used HIPing by pressure assisted sintering. in a variety of particle sizes at competi- components ranging in weight from 1.8 m x 3.3 m 1.8 m x 3.3 m primarily for the HIPing of ceramic The container is removed by rough tive prices. 100 g to 15 t covering high alloyed 14 h cycle time 8 h cycle time materials but also for HIPing of machining and/or pickling to reveal The conversion of gas atomised steels, stainless steels, Ni and Co base cemented carbides (WC-Co materials). the near net-shape component. powders into 100% dense products alloys and metal matrix composites 4 hour hold time 4 hour hold time Properly operated and maintained Compound products can also be having near-net shape components (MMC). 20 tons/cycle 2 tons/cycle the furnace will perform flawlessly produced by designing capsules with often weighing several tonnes, with a This has given the company a 10000 tons per for more than 10 years of continuous, separate compartments for different refined microstructure and mechanical foothold in the offshore components 1800 tons per year year demanding service. powders or enclosing parts of solid properties superior to cast or wrought market, utilising its near net shape 0.3 EUR/kg 0.9 EUR/kg Avure’s Uniform Rapid Cooling material together with the powder. equivalents, has made hot isostatic expertise to produce complicated high (URC) technology and quench furnaces Recent developments in computer pressing an essential PM processing alloy PM HIPed components, including Fig. 5 Examples of HIP cost reduction are equipped with a forced convection modelling of the HIP process by the route for a growing number of applica- for subsea development projects. using large HIP systems [3] system which circulates cooler gas French consortium of SNECMA, tion areas. Areas of importance are HIPed through the work zone. Cooling rates Turbomeca, and Tecphy (now Aubert components for multi-fluid analysis, of 100°C/min (above 800°C) and a & Duval) and also VILS in Russia, PM high alloy steels wye-pieces for pipeline installations, heating rate of 30°C/min for a D=1.2 have led to the production of complex manifolds for topside and subsea meter hot zone with a 2000 kg load can near-net HIP shapes to very high The use of HIP to produce PM tool installations, valve bodies for choke be achieved without affecting the size dimensional precision with critical steels was developed simultaneously, and control valves, and swivels for of the hot zone significantly. surfaces held to within 0.25 mm. but independently, in Sweden by Stora FPSOs. Kopparberg and ASEA (now Erasteel) Manifolds are, for example, used and by Crucible Materials Corp in the for collecting oil/gas from well heads “Recent developments in computer USA (Crucible Particle Metallurgy as well as for water injection. They Process – CPM) in the 1970’s. are subjected to sour service and high modelling of the HIP process have led to the The use of gas atomised tool steel pressure, and therefore require high powders and HIP led to the elimina- mechanical strength and corrosion production of complex near-net HIP shapes tion of segregation found in cast resistance (Fig. 10). The Duplex to very high dimensional precision” materials, and the very fine distribu- stainless FPSO Swivel component has tion of primary carbides in the HIPed internal passages for oil/gas, water microstructure resulted in superior injection and power connection. For smaller HIP vessels this Powder based HIP mechanical properties such as Although Metso Materials Tech- temperature change rate, including products compressive strength, hot hardness, nology no longer produces HIPed the load, can be 300°C or even 400°C, and toughness. components in-house, the company’s Fig. 8 (top) Pre-HIP filled can weighing depending on the vessel size [4]. The HIP systems described above have The high wear resistance of PM Engineered Materials & Components 2050 kg with 1525 max OD; (middle) This provides decreased cycle time, often been designed for specific appli- tool steels helped to secure increasing Division in Lokomo, Finland, continues post-HIP 1345 mm maxOD; (bottom) heat improved productivity, and can even cations such as converting powder treated and sonic machined HIPed part [5] combine HIP and heat treating. Fig. 7 into fully dense products (metal, (Courtesy Carpenter Technologies) shows a typical HIP cycle for an Avure carbide and ceramics) by pressure “The use of gas atomised tool steel Quintus® system with and without assisted sintering, post-HIP of sintered powders and HIP led to the elimination URC. products to eliminate porosity, and the Fig. 6 Schematic of a modular plug-in production of bimetallic products. of segregation found in cast materials” wire wound HIP vessel produced by Avure Containers for powders The HIP temperatures can range Technologies with multiple heating zones from 1100°C for powder consolidation and patented insulation mantle design [2] Whilst solid metals such as castings of PM tool steels, to 1500°C for the market share in the intervening to develop and use HIP technology for or sintered parts can be loaded directly elimination of porosity in hardmetals decades and they are now extensively a growing range of applications. into the HIP furnace, blended metal or (cemented carbides), and exceed used in metal forming tools and other One example given by the company alloy powders are first filled into high 2000°C for HIPing of ceramics. applications. [6] is a superaustenitic 254 SMO quality steel containers which must be Pressures of up to 200 MPa can be PM high speed steels are also stainless steel ball valve used in a strong enough to maintain shape and achieved. The length of the HIP cycle produced by the HIPing of gas desulphurisation plant in oil refineries. dimensional control but be soft and can take several hours so there are atomised powders, and one example The HIPed components are required to Fig. 9 HIPed gear cutting hob from malleable at the HIPing temperature. economic advantages in having as big is the HIPed gear cutting hob shown operate in a highly corrosive hydrogen MICOPCLEAN high alloy high speed steel An example of a container filled with a workload in the press as possible. in Fig. 9. These PM HSS materials sulphide environment containing oil/ powder. (Courtesy Böhler-Uddeholm Alloy 625 powder is shown in Fig. 8 [5]. The development of ‘mega’ (1.6 m are said to bridge the gap between gas. The as-HIPed valve half is shown Powder Technology) The standard container is between diameter) and ‘giga’ HIP (2.05 m diam- conventional high-speed steels and on the left in Fig. 11 after the removal 2 and 3 mm thick. Containers are eter) systems in recent years has come cemented carbides. of the HIP capsule and Fig. 11 right normally degassed at intermediate alongside the significant increase in The early landscape of PM high shows the as-machined part. The temperatures (ca. 300°C), sealed, powder production capacity, particu- alloy steel producers has changed HIP route produced a material with preheated and then HIPed in a larly high grade spherical shape significantly over the past decade. superior properties and allowed easy pressure vessel. In the case of PM powder particles suitable for HIP ASP® grades are now produced by and reliable ultrasonic inspection. superalloys, typical HIP conditions are produced by gas atomisation. Erasteel, a member of the ERAMET Undoubtedly one of the most a temperature of between 1100 and This has resulted in a wide choice Group. impressive Metso applications for 1260°C and a pressure of 100 to 200 of alloy powders such as stainless When Sandvik Powdermet, based in PM high alloy steels are the stainless MPa, which is maintained for several steels, tool steels and high speed Surahammar, Sweden, acquired Metso steel end covers for the CERN particle Fig. 10 Offshore manifold system in Super Fig. 7 HIP cycle for a large Quintus® hours with argon as the pressurising steels, as well as nickel-based and Powdermet AB from the Finnish Metso accelerator located in a 27 km long Duplex stainless material. Total weight system with and without URC [2] (Courtesy medium. The superalloy powders are cobalt-based super alloys which are Oy Group in 2006, it acquired a leading ring-shaped tunnel 100 m under- of the manifold is 26 tonnes. (Courtesy Avure Technologies) consolidated to full density during now being produced in large quantities producer of near-net-shape HIPed PM ground near Geneva. The choice of end Sandvik Powdermet)

and with high creep resistance at the Group (EPHG). Adeline Riou (Erasteel, References [6] P. Siitonen (Metso Materials rim [7]. France), chair of the EPHG, stated Technology, Finland), ‘PM HIP Compo- A further significant development that collective actions by the trade [1] S. Davies. ‘HIPing – The Process and nents for O&G and Other Demanding has been the computer modelling associations can be an effective way its Applications in Materials Manufac- Applications’. Presentation at Workshop of the HIP process, which has led to to improve the awareness of HIP. The ture’. Presentation at Workshop on HIP on HIP Processing of Materials for the production of NNS PM superalloy group has published a free educational Processing of Materials for Aggressive Aggressive Environments’, Derby, components. A French consortium of brochure on HIP that can be down- Environments’, Derby, November 16, November 16, 2011. SNECMA, Turbomeca and Tecphy (now loaded as a PDF. 2011. [7] G. Raisson (Aubert & Duval, France). Aubert & Duval) and separately VILS The EPHG will be organising a [2] A. Eklund. ‘A HIP Future – The Latest Presentation at Workshop on HIP in Russia have successfully developed Special Interest Seminar on ‘Materials Developments in HIP Technology’. Processing of Materials for Aggressive modelling technology to produce Properties & Materials Selection for Presentation at Workshop on HIP Environments’, Derby, November 16, Fig. 11 (left) As-HIPed body part for ball valve with capsule removed and heat treated. complex shaped as-HIPed compo- Hot Isostatic Pressing’ (Wednesday, Processing of Materials for Aggressive 2011. (right) HIPed body part as-machined [6] nents. As-HIPed PM superalloy turbine September 19 2012) to coincide Environments’, Derby, November 16, [8] G. Raisson, etal (Aubert & Duval, discs produced by VILS are shown in with the EuroPM2012 Conference 2011. France). ‘Production of Net-Shape cover material was a fully dense HIP Fig. 13. An as-HIPed turbine casing and Exhibition scheduled for Basel, [3] A. Riou, S. Olsson. ‘Trends and Static Parts by Direct HIPing of Nickel- stainless steel 316LN grade of which made from SYP3 (Astroloy-type grade Switzerland, September 16-19 Applications in PM HIP Technology’. base Supealloy Prealloyed Powders’. Metso supplied some 2700 pieces, PM superalloy) for the SNECMA CFM (www.epma.com/pm2012). Paper in Proceed. Of International Paper presented at Euro Superalloys (Fig. 12). Metso has also supplied 56-5 aero engine is shown in Fig. 14. A technical session devoted to HIP Conference on Hot Isostatic Pressing’, 2010, and published in Advanced around 20 tonnes of HIPed PM stain- took place at the PowderMet 2012 Kobe, Japan, April 2011, pp 7-11. Materials Research, Vol 278, 2011, pp less steel 316LN radial plates for the Sputtering targets Conference & Exhibition, Nashville, [4] M. Gärdin. ‘New Opportunities using 277-292. ITER fusion reactor project. USA, June 10-13 (www.mpif.org), and the next generation HIP equipment’. [9] S. Davies (Bodycote HIP Ltd, UK). Bodycote in Surahammar, Sweden, Another significant application for hot will also feature at the PM2012 Powder Paper in Proceed. Of International ‘HIPing – The Process and what you can has since 2010 also been operating isostatic pressing is the production of Metallurgy World Congress & Exhibi- Conference on Hot Isostatic Pressing’, do with it’. Presentation at Workshop on Fig. 12 HIPed stainless steel 316LN end a very large HIP unit and Erasteel sputtering targets used for coatings, tion, Yokohama, Japan, October 14-18, Kobe, Japan, April 2011, pp 169-172. HIP Processing of Materials for Aggres- covers for CERN particle accelerator. [6] doubled its powder production capacity magnetic memory materials and (www.pm2012.jp). [5] L. Lherbier (Carpenter Technologies, sive Environments’, Derby, November in Söderfors, also in Sweden, opening microelectronic layers. High purity, Further information on the activi- USA), ‘An Alternative Fabrication Tech- 16, 2011. a new large capacity gas atomiser in homogenous materials with 100% ties of the isostatic pressing groups nology for Complex Shapes’. Presenta- 2011. density can be produced from chro- can be obtained from the two trade tion at Workshop on HIP Processing of mium, refractory metals, ceramics or associations: www.mpif.org and www. Materials for Aggressive Environments’, PM superalloys other materials which cannot be made epma.com. Derby, November 16, 2011. by melting technology. Improvements in gas atomisation HIPed sputtering targets may technology to produce finer, cleaner, be further HIP diffusion bonded to high purity nickel-base powders has a suitable supporting substrate or seen PM superalloy near net shape backing plate. Bodycote HIP, a leading (NNS) components produced by HIP Fig. 13 As-HIPed PM superalloy parts for producer of HIPed components and find increasing applications in the aero turbine discs and compressor discs having provider of HIP services, has developed and land based gas turbines as well as diameter 150 – 950 mm and weighing up capsule technology which the company other sectors such as energy. states opens up a range of sizes, ipmd.net to 300 kg (Courtesy VILS Joint Stock Co) Static and dynamic mechanical designs and chemical composition of properties of HIPed superalloy sputtering targets. Fig. 15 shows some products can be at the level of, or very HIPed chromium powder billets. close to, extruded + forged products The online resource for [7]. HIP parameters and final heat treatment conditions can be readily Promoting HIP technology adapted to control the grain size and Although the first in a series of precipitate distribution in the micro- successful international conferences the PM industry structure of the PM superalloys. on isostatic pressing was organised This has led to the development by the author and his team at MPR of specific PM superalloy grades Publishing in the UK as early as Fig. 14 As-HIPed turbine casing made from • News & technical with higher alloying content than 1978, and a specific ‘International SYP3 PM superalloy by Aubert & Duval for conventional cast and wrought grades, HIP Conference’ series was started reviews the SNECMA CFM 56-5 aero engine [8] which allow aero engines to withstand in Lulea, Sweden in 1987, the aware- higher combustion temperatures and ness of PM HIP technology and its • Industry directory pressure ratios resulting in increased potential was still considered to be fuel efficiency and performance. It limited compared with some other PM • Technology & would be difficult, if not impossible, to technologies. produce similar superalloy composi- In 2009 the MPIF established a market data tions by the cast and wrought routes. separate ‘Isostatic Pressing Associa- The HIP route also allows the tion (IPA)’ in North America to provide • Free weekly production of bi-metal parts with dual more information and education e-newsletter properties. One example is a turbine on the area, and in 2010 the EPMA Fig. 15 Chromium (PM) sputter targets/ disk with high yield strength at the established a European counterpart billets (Courtesy Bodycote HIP Ltd) [9] intermediate temperatures in the hub in the form of the European PM HIP

North America’s Powder Metallurgy industry maintains its growth momentum

In comments delivered during the opening session of PowderMet 2012, the International Conference on Powder Metallurgy & Particulate Materials, Nashville, USA, June 10-13, Matthew Bulger, President of the Metal Powder Industries Federation, stated that in all materials, process and market sectors, the North American Powder Metallurgy (PM) industry has built on the growth momentum that began last year.

“Traditional press-and-sinter PM, The HIP business has also Sustained growth ahead Metal Injection Moulding (MIM), experienced robust growth in 2011 due Hot Isostatic Pressing (HIP), and to a general surge in manufacturing Bulger stated that 2012 began on a other specialty PM technologies and gains in the oil-and-gas, tool-steel very positive note, with rising confi- are thriving,” stated Bulger. “PM is and aerospace markets. The HIPing of dence levels. First-quarter shipments an interconnected technology that MIM parts, noted Bulger, continues to of metal powders are up, as are innovates and grows by leveraging its be a growing market. volumes of PM parts and MIM parts. different sectors.” Looking back at the past two years, it was suggested that the industry’s recovery is sustainable. Iron powder shipments soared in 2010 after a difficult previous year. Total North American iron-powder shipments grew modestly in 2011 to 363,831 short tons, a 3% increase that was achieved despite the shutdown of a major powder supplier’s main plant for two months. Shipments of copper and copper- based and tin powders gained almost 19% in 2011 to 17,002 short tons. Fig. 1 North American iron powder shipments (Courtesy MPIF) Stainless steel powder shipments increased about 5% to an estimated 7,000 short tons. Shipments of North American MIM grade powders, including imports, jumped nearly 40% in 2011 and the MIM process, it was suggested, continued to garner greater accept- ance in the materials marketplace. Some interesting R&D programmes were highlighted, included MIM ultrasonic dental scaler tips and endodontic tips, as well as titanium and cobalt– chromium alloys for medical implant Fig. 2 North American shipments of copper, copper-based and tin powders applications. (Courtesy MPIF)

Lightweight materials The growing demand for lightweight materials is encouraging new attention aimed at PM aluminium, titanium, and Award winning parts magnesium structural applications. Boeing, it was stated, has recently qualified PM titanium alloy products demonstrate Powder Metallurgy’s for commercial aircraft use as an alternative to machining parts from bar, plate, castings, forgings, or many advantages for critical extruded products. Copper-powder products also offer new opportunities for growth. applications Applications that take advantage of copper’s conductivity properties, as Winning parts in the Metal Powder Industry Federation’s (MPIF) 2012 Powder Fig. 3 Matthew Bulger, President of the MPIF, welcomes delegates to PowderMet 2012 well biomedical applications offer significant opportunities. Metallurgy Design Excellence Awards competition were announced at the PowderMet 2012 International Conference on Powder Metallurgy and U.S. light-vehicle sales are expected auto-engine content with existing High performance PM equipment to top 14 million units, up substantially technology. The average auto engine PM equipment suppliers, commented Particulate Materials, Nashville, USA, June 10-13. In this article we present all from the 12.8 million units sold in now contains up to 50 PM parts Bulger, are striving to advance the the award wining components. 2011. weighing more than 18 pounds, technology with new products such Iron-powder shipments through including connecting rods, bearing as larger tonnage CNC hydraulic April this year rose by 11.25% to caps, valve-seat inserts, and VVT parts. compacting presses, more-stringent 134,925 short tons. Copper and With the average North America– tolerance capabilities in the micron copper-base and tin powder shipments built engine containing up to 170 The following award winning parts limit. The adapter is formed to a density range, upgrading controls on older 3 have remained stable. individual parts, PM parts currently exemplify PM’s special engineering of 6.9 g/cm , and has a minimum compacting presses, and high- benefits, namely net shape, preci- ultimate tensile strength of 58,000 psi, represent about 30% of the content. performance sintering furnaces. Capacity constraints Potential growth appears more likely, sion, innovative fabrication methods, and yield strength of 53,000 psi. “One of the key issues facing the entire it was stated, in transfer-case and production efficiency, energy and After sizing and grinding, there is industry is the serious need for expe- transmission applications. PM Industry Roadmap materials savings, and manufacturing no other machining performed on the rienced production workers and PM Educating automotive engineers cost reduction. rotor. The adapter is not machined Bulger reported that an updated PM These advantages, states the prior to assembly and is made to net engineering professionals. Industry- about PM’s benefits has always been Industry Roadmap, a project of MPIF’s wide employee reductions during an important aim of the MPIF Industry MPIF, continue to stir designers to shape with vertical slots for oil feeding. Technical Board, Industry Develop- choose PM for critical applications However, the customer machines the ment Board, and numerous additional in auto engines and transmissions, cross holes for the oil feed. “The average auto engine now industry experts, has been recently electronics, medical devices, agricul- released. Based on the first Roadmap tural equipment, consumer products, Automotive: Transmission contains up to 50 PM parts weighing completed in 2001, the update shows military, and emergency applications. GKN Sinter Metals also won the grand that the industry has made steady In an increasing number of design prize in the automotive transmission more than 18 pounds” progress in high-density processing, decisions, PM jumps to the front of the category for a unitized one-way clutch new materials, 3-D forming systems, line ahead of traditional forging, die (OWC) module (Fig. 2)) made for the modelling, and advanced manufac- 2008–09 have not been easy to reverse Development Board (IDB). This year, casting, stamping, investment casting, Chrysler Group LLC, Auburn Hills, Fig. 1 PM steel rotor and adapter used in a turing methods. and machining processes. Michigan. as the industry has rebounded.” stated Bulger, the IDB launched a new Looking ahead, the new Roadmap VVT rotor adapter assembly Another issue highlighted was Automotive Showcase programme The module has four PM steel parts identifies three main topics that will (powder-forged race and cam, and capacity constraints, “Will the industry to bring PM’s design-benefit-value impact the industry’s growth: high- Grand Prize Awards be ready to meet rising demands, message to PM’s single largest two pressed-and-sintered retainer density PM components, processing of Automotive: Engine particularly driven by the automotive market. plates) as well as 22 additional parts lightweight materials, and electrical GKN Sinter Metals, Auburn Hills, industry, in the next several years?” (clips, springs and roller elements). and electromagnetic applications. Michigan, USA, won the grand prize in asked Bulger. This product is the first self-contained PM technology While the current PM industry is driven the automotive engine category for a As was the case with staffing, loose-roller OWC module for torque by automotive applications, growth in VVT rotor adapter assembly consisting rationalisation moves during the same developments converter stator applications using the next decade must be found in other of a PM steel rotor and adapter (Fig. 1). all PM and powder-forged main 2008–09 period included several plant The machinability of PM materials markets. The overall need for alterna- The parts are joined by an adhesive, components. closings and the scrapping of older New additives that improve the tive energy sources should open new which joins them during machining of The retainer plate has net-shape equipment. “Because it can take machinability of PM materials were markets and applications for PM. cross holes and other features on the features that cannot be formed by upwards of 10 to 12 months to build highlighted as a significant advance- In closing, Bulger noted that the PM inside diameter, and seals the joint other manufacturing processes a high-end metal powder press and ment. “As mechanical-property industry is truly unique for its close- between them. without major secondary operations. put it into production, the equipment demands rise, so does the need to knit band of large and small compa- The assembly, used in a Chrysler Selecting the PM process reduced investment bandwagon must begin improve the machining performance nies who are devoted to promoting the V-6 engine, is mounted to the engine production costs by 20% and increased rolling sooner rather than later.” of sinter hardened and heat-treated entire industry and encouraging its camshaft. Formed to a density of 6.8 g/ the volume rate by 50%. PM’s reli- materials.” Researchers, it was stated, growth. By being truly interconnected cm3, the rotor has an ultimate tensile ability is supported by more than 10 The automotive sector are also developing new lubricants for globally, the industry will continue to strength of 60,000 psi, yield strength million OWC assemblies in the field Fig. 2 Unitized one-way clutch module Within the automotive sector, PM high-density applications. succeed and thrive in the years ahead. of 55,000 psi, and a 23,000 psi fatigue with zero warranty claims. used in automotive transmissions is approaching a saturation point in www.mpif.org

Made to a density of 7.4 g/cm3, the complex three dimensional geometry part has an ultimate tensile strength of incorporating assembly pins and slots 110,000 psi, 75,000 psi yield strength, for moving the internal parts that and 100 ft/lbf unnoticed Charpy require smooth action for suturing. impact strength. Maintaining the Formed to a net shape requiring no density between the hub and flange machining, the parts are assembled is especially critical. The part has two by the customer who performs laser PM posts manufactured and installed welding on the cover seam/joint. The while maintaining true position and parts are made to a density of 7.65 squareness. g/cm3. Choosing the MIM process Secondary operations include provided a 70% cost savings over adding the tapped posts, two slots on equivalent machined parts. the shelf flange, two counterbores, and a countersink. PM was selected Electrical/Electronic Components Fig. 3 PM two-stage helical gear and spur Fig. 5 Copper-infiltrated PM steel inside over castings and stampings, which The grand prize in the electrical/ Fig. 7 Mechanical introducer device used Fig. 9 PM steel alloy power take-off clutch pinion used in a power liftgate actuator deadbolt chassis could not meet strength or Builders electronic components category was in minimally invasive surgery hub Hardware Manufacturers Association won by Capstan California Inc., Carson, requirements for integrity during California, and its customer Reli- high-temperature tests. able Security Group Inc., Signal Hill, California, USA, for a soft magnetic PM Aerospace/Military alloy coil housing used in a magnetic FloMet LLC, Deland, Florida, USA, door closer for emergency/fire protec- won the grand prize in the aerospace/ tion applications (Fig. 8). military category for a very complex Formed as a single shape to a 17-4 PH stainless steel rotor (Fig. 6) density of 6.8 to 6.9 g/cm3, the new made by metal injection moulding PM design replaced a three-piece (MIM) and used in a hand-emplaced assembly. Critical design features munition device. include the locations of drafts, radii, The intricate design is demon- and chamfers, as well as redefining strated by its four holes on two tolerances for a near-net shape part. perpendicular planes, two angled slots Secondary operations include resin with square corners, and numerous impregnation and zinc plating. The Fig. 8 Soft magnetic PM alloy coil housing Fig. 10 Stainless steel MIM top and bottom Fig. 4 PM steel gear race used in the Fig. 6 Stainless steel rotor used in a hand- internal and external radii, flats, slots, one-piece design provided a 21.5% cost used in a magnetic door closer of an eyeglass-frame bridge OnTrac2 GPS-assisted steering system emplaced munition device and cutouts. All of these features savings over the previous assembly. require very tight tolerances: 0.0025 Featuring very thin walls, the parts Automotive: Chassis planting and harvesting equipment inches to 0.005 inches. Moreover, the Industrial Motors/Controls & form the bridge section over the nose, The grand prize in the automotive to more accurately perform tillage, square bottom-hole could only be Hydraulics which also houses an actuator for chassis category was awarded to spraying, and spreading as well as formed by MIM because prior attempts Capstan Atlantic, Wrentham, Massa- changing the magnification level of Capstan Atlantic, Wrentham, Mass., reducing skips and overlaps, thus with other fabrication processes, chusetts, USA, won the grand prize the glasses. The as-sintered density is USA, for a complex PM steel two-stage reducing fuel consumption. Moulded including machining, proved in the industrial motors/controls & 7.6 g/cm3. helical gear and spur pinion used in a to a density of 6.7 g/cm3, the part has unsuccessful. hydraulics category for a PM steel power liftgate actuator (Fig. 3). an ultimate tensile strength of 60,000 It is estimated that the machined alloy power take-off clutch hub (Fig. 9). Made to a nominal density of psi, minimum yield strength of 50,000 version of the part could cost as much Formed to a density of 7.05 g/cm3, Awards of Distinction 6.85 g/cm3, the combined helical gear– psi, 125,000 psi transverse rupture as five times that of the MIM design. the complex multi-level part replaced and-pinion design features precision strength, and 23,000 psi fatigue limit. The rotor is made to a density of a machined design. Automotive: Engine journals for precise orientation in The complex net-shape design 7.5 g/cm3 and has an ultimate tensile Typical properties include an SolidMicron Technologies Pte Ltd., the actuator assembly. The part has features 112 gear teeth and 16 strength of 75,000 psi, yield strength ultimate tensile strength of 80,000 psi, Singapore, won the first award of Fig. 11 A 440C stainless steel MIM sealing a tensile strength of 65,000 psi and a assembly holes. In addition to a of 25,000 psi, a six percent elongation, yield strength 90,000 psi and a 92 HRB distinction in the automotive-engine seat used in a direct fuel injector assembly yield strength of 55,000 psi. 60% cost savings over the previous and 27 HRB hardness. apparent hardness. category for a 440C stainless steel The precise elemental gear data machining method of making the The part is designed to withstand MIM sealing seat used in a direct fuel tolerances enable quiet gear perfor- part, the PM design reduced the Medical/Dental very high torque levels in service and injector assembly (Fig. 11). mance, decreasing noise, vibration, assembly part count from 24 to six Parmatech Corporation, Petaluma, the flange is strong enough to resist Made for Magneti Marelli S.p.A. and harshness. parts. Selecting PM also cut lead times California, USA, won the grand prize repetitive bending fatigue. Powertrain, Bologna, Italy, the complex and allowed for easier assembly and in the medical/dental category for a part has a multiple angled slot and top Lawn & Garden/Off-Highway disassembly in the field. mechanical introducer device used in Consumer holes requiring precise tool design and FMS Corporation, Minneapolis, Minne- minimally invasive OB/GYN surgery The grand prize in the consumer fabrication. sota, USA, won the grand prize in the Hardware/Appliances (Fig. 7). market segment category was won The near-net-shape part has a lawn & garden/off-highway category A copper-infiltrated PM steel inside Made for STD Med, Stoughton, by Smith Metal Products, Lindstrom, density range of 7.54 to 7.65 g/cm3, for a PM steel gear race (Fig. 4) used deadbolt chassis (Fig. 5) made by ASCO Massachusetts, USA, the device Minnesota, USA, for a 17-4 PH a tensile strength of 232,000 psi, and in the OnTrac2 GPS-assisted steering Sintering Co., Commerce, California, contains five 17-4 PH stainless steel stainless steel MIM top and bottom yield strength 203,000 psi. system made for Novariant Corpora- USA, for a new commercial electronic MIM parts: right and left cover, curved of an eyeglass-frame bridge (Fig. 10) The MIM process provided a tion, Fremont, California, USA. lock system won a grand prize in the needle, curved needle linkage, and made for Superfocus LLC, Van Nuys, 30%–40% cost savings over alternative Fig. 12 Soft magnetic solenoid core used in The system positions agricultural hardware/appliances category. centre linkage. The covers have a California. manufacturing processes. a high-pressure diesel-engine fuel injector

3 Group, for a PM steel synchroniser hub Made to a density of 7.6 g/cm , the controls & hydraulics category for made for Aichi Machine Industry Co., parts are produced to net shape with 316L and 440C stainless steel parts Ltd., Japan (Fig. 13). only four requiring minor secondary (catch X-Z datum, catch bias Z datum, The complex five-level part is used operations such as reaming and front and rear support tabs) used in an in the first and reverse gears in a coining. industrial printer module (Fig. 19). double-clutch transmission. Powder Achieving a yield strength rate of Metallurgy provided a 25% cost saving Industrial Motors/Controls & 234,000 psi, the 440C tabs support over a broached steel part. Hydraulics and align the print head module and Capstan California and its customer are subjected to impact force during Automotive: Chassis Sperry Product Innovation Inc., printing. ACL Bearing Company, Tasmania, Woburn, Massachusetts, USA, won the The 316L catches guide and feed Australia, won the award of distinction award of distinction in the industrial paper to the printing module. Choosing motors/controls & hydraulics category the MIM process over casting and Fig. 19 316L and 440C stainless steel MIM in the automotive chassis category parts used in an industrial printer module for a PM sinter-brazed spacer tube for a porous bronze filter used in a machining yielded a 40% cost savings. Fig. 13 PM steel synchronizer hub used in Fig. 16 Seven-level rack used in an (Fig. 14) made for Futuris Automotive solvent pumping purification system a double-clutch transmission industrial washing machine Interiors (Australia) Pty Ltd, Edin- (Fig. 18). Electrical/Electronic Components burgh, South Australia, and used in a The filter is gravity sintered to Smith Metal Products, Lindstrom, 3 steering-column tilt/reach assembly. a density of 5.1 to 5.2 g/cm . The Minnesota, USA, won the award of Formed to a density of 6.8 g/cm3, special mould design eliminates most distinction in the electrical/electronic the complex part has a tensile strength secondary operations on the part, components category for a 17-4 PH of 65,000 psi, 50,000 psi yield strength, except for deburring the edge. It also stainless steel lever made for Methode 7% elongation, and 60 HRB hardness. allows step grooves to be moulded into Electronics, Harwood Heights, Illinois PM provided a 40% cost savings the part. (Fig. 20). over fabricating the part by broaching. The intricate MIM part is used in a Industrial Motors/Controls & latch ejector mechanism for pluggable Lawn & Garden/Off-Highway Hydraulics gigabit Ethernet connections. Porite Taiwan Co., Ltd., Taiwan, ROC, Advanced Materials Technologies Pte. www.mpif.org won the award of distinction in the Ltd., Singapore, won the other award Fig. 20 Stainless steel MIM lever used in a lawn & garden/off-highway category of distinction in the industrial motors/ latch ejector for Ethernet connections for a PM steel gear used in an output box in a tiller transmission (Fig. 15). Fig. 14 PM sinter-brazed spacer tube used Fig. 17 Six 17-4 PH stainless steel MIM Made for Pubert SAS, Chantonay, in a steering-column tilt/reach assembly parts are used in this cable-tie hand tool France, the complex part is made to a PowderMet 2012 Nashville density of 6.8 g/cm3. It has an ultimate tensile strength of 104,000 psi, 131,000 psi compressive yield strength, and a minimum 28 HRC hardness.

Appliance Capstan Atlantic, Wrentham, Massa- chusetts, USA, won the appliance category award of distinction for a seven-level rack used in an industrial washing machine (Fig. 16). Made to a density of 6.8 g/cm3, the part has sectional density that is kept equal within 0.08 g/cm3. The part has Drew Winter, Wards Auto World Magazine The PowderMet Welcome Reception Fig. 15 PM steel gear used in an output Fig. 18 Porous bronze filter used in a a minimum yield strength of 43,000 psi box in a tiller transmission solvent pumping purification system and typical 55,000 psi tensile strength. PM replaced a die-cast part that Automotive: Engine shape 7.5 g/cm3 density. Proprietary needed extensive machining. Burgess Norton Mfg. Co., Geneva, compacting and thermal processing Illinois, USA, won the other award produce a high-strength core with Recreation of distinction in the automotive superior magnetic properties. Megamet Solid Metals, Inc., Earth engine category for a soft magnetic The part is made from a high-purity City, Missouri, USA, won the award of solenoid core (Fig. 12) for its customer iron powder with an inorganic coating distinction in the recreation category Cummins Inc. electrically insulating the particles. for a cable-tie hand tool assembly Used in a high-pressure diesel- of six 17-4 PH stainless steel MIM engine fuel injector, the core has a Automotive: Transmission parts (pinion, nosepiece, pawl gripper, difficult-to-form deep pocket with high The award of distinction in the auto- insertable rack, cutoff cam, and short wall aspect ratios. motive transmission category was won link) made for HellermannTyton, The part is pressed to a net- by the Asturias/Spain plant of the PMG Milwaukee, Wisconsin, USA (Fig. 17). The PowderMet 2012 exhibition Guests at the PowderMet 2012 Welcome Reception

36 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd © 2012 Inovar Communications Ltd Autumn/Fall 2012 Powder Metallurgy Review 37 MIM2013_Sept 2012_Layout 1 8/14/2012 10:13 AM Page 1

The results of two separate Powder Metallurgy aluminium alloy developments, Call for Presentations for MIM2013 pursued through collaborations between GKN Sinter Metals and Dalhousie Innovation in different segments of powder injection molding (PIM) is responsible for the rapid growth of University and aimed at two diverse types of PM press/sinter application, were this field. The PIM industry (MIM—metal injection molding; CIM—ceramic injection molding; and CCIM— revealed in presentations at MPIF’s PowderMet 2012 Conference in Nashville, cemented carbide injection molding) has estimated sales of over $1 billion and could possibly double in a Tennessee, June 10-13, 2012. Dr David Whittaker reviews these papers span of five years. exclusively for Powder Metallurgy Review/ipmd.net. The objective of the conference is to explore the innovations and latest accomplishments in the areas of part design, tooling, molding, debinding, and sintering of PIM parts. The conference will also focus on the developments in PIM processing of different materials including metals and alloys, ceramics, and hardmaterials.

This specialized conference is sponsored by the Metal Injection Molding Association, a trade association Effects of zirconium Alloy Al Cu Mg Sn Zr Lubricant of the Metal Powder Industries Federation, and its affiliate APMI International. With its focus on additions on the sintering A Bal. 2.3 1.6 0.2 --- 1.5 “Advances in Component Uniformity,” the conference is targeted at product designers, engineers, response of an Al-Cu-Mg B Bal. 2.3 1.6 0.2 0.2 1.5 consumers, manufacturers, researchers, educators, and students. All individuals with an interest in the PM alloy C Bal. 2.3 1.6 0.2 0.2 1.5 application of powder injection molding will be encouraged to attend. The first of these twin papers was Table 1 Nominal compositions (wt%) for the alloys studied (Courtesy MPIF) presented by Paul Bishop (Dalhousie DEADLINE FOR ABSTRACT SUBMISSION IS SEPTEMBER 30, 2012 University, Halifax, Nova Scotia, Blend Flow Rate (g/s) Apparent Canada) on behalf of his co-authors, Density (g/cc) Randy W Cooke (Dalhousie University) MIM2013 CONFERENCE (March 5–6) A 2.9 1.19 Table 2 Flow rate and and Richard L Hexemer Jr. and Ian apparent density results for B 2.7 1.30 A two-day event featuring presentations and a keynote luncheon Donaldson (GKN Sinter Metals LLC, the alloys studied (Courtesy Auburn Hills, USA). C 2.9 1.17 MPIF) • Designing MIM Parts and Materials for Performance and Value This development was aimed at enhancing the capabilities of materials • Part Selection—Best Practices Alloy Compaction Green Density Green for PM structural part applications. Pressure Strength (g/cc) (% Theoretical) • Leading Process Trends The reported work built on previous (MPa) (kPa) studies from the same collaborative A 200 2.509 92.1 6823 • Numerous Case Studies team that had revealed the develop- 400 2.602 95.5 8438 ment of a new Al-Cu-Mg PM alloy (Al- • Tabletop Exhibition & Networking Reception with Representatives 2.3Cu- 1.6Mg- 0.2Sn) and specifically 600 2.615 96.0 8528 from Many of the Leading Companies in the Field related to the potential benefits of B 200 2.509 92.0 6540 making small additions of zirconium to 400 2.604 95.5 9783 ...and Much More! this base alloy system. 600 2.621 96.1 9830 Zirconium is recognised to confer Optional One-Day Powder Injection Molding Tutorial Precedes Conference (March 4) a range of benefits in wrought Al C 200 2.536 93.0 5359 alloys (e.g. creation of precipitation 400 2.615 95.9 7142 Taught by Randall M. German, world-renowned PIM expert hardening, improvement in recrystal- 600 2.626 96.3 7279 lisation resistance), but its use in An ideal way to acquire a solid grounding in powder injection molding technology in a short period of time press/sinter PM alloys had not been Table 3 Green density and green strength data for the alloys studied (Courtesy MPIF) • Introduction to the manufacturing process previously tested. The three powder mixes used in Alloy B comprised the same Initially, it was confirmed that the Zr • Definition of what is a viable PIM or MIM component this study (Table 1) were all based ingredients together with an Al-50Zr additions exerted no significant influ- • Materials selection and expectations on the emerging Al-Cu-Mg composi- masteralloy as the source of zirco- ence on either flow rate or apparent • Review of the economic advantages of the process tion. Alloy A was the “base” alloy nium. Alloy C had the same bulk density of the base alloy (Table 2). comprising air atomised elemental composition as B, but, in this case, Green density and green strength were aluminium, inert gas atomised the zirconium was prealloyed in the assessed next for a range of compac- elemental magnesium and tin and an base aluminium powder rather than tion pressures (Table 3). This conference is sponsored by the Metal Injection Molding Association, Al-50Cu masteralloy. being added as a masteralloy. The results for alloys A and B a trade association of the Metal Powder Industries Federation

were fairly comparable, although the • It offers an enhanced combination Sintered Density Dimensional Change (%) zirconium-containing alloy B showed of mechanical performance and Alloy somewhat increased green strengths. dimensional control capability (g/cc) (% Theoretical) OAL Width Length Spread Alloy C showed a lower increase compared with standard commer- A 2.716 99.7 -4.52 -2.73 -1.57 2.9 of green strength as compaction cial PM aluminium alloys. B 2.719 99.7 -4.82 -2.56 -1.98 2.8 pressure was increased and it was • It may open up the possibility of C 2.719 99.7 -3.24 -2.33 -2.13 1.1 proposed that this resulted from the advancing the level of geometrical pre-alloyed nature of the Zr addition. complexity achievable in PM Table 4 Sintering response for the alloys studied. All bars compacted at 200MPa (Courtesy MPIF) It was found that all three alloys aluminium products, in order to Alloy Apparent Hardness (HRE) Yield (MPa) UTS (MPa) Elongation (%) sintered to near full theoretical density form challenging features such as (Table 4) and the comparative levels of thin walls. A 93.4 ± 0.1 191 ± 6 303 ± 9 7.5 ± 1.7 sintered mechanical properties were Fig. 1 Images acquired through 3D laser Fig. 3 Images acquired through 3D laser B 93.0 ± 0.3 185 ± 11 294 ± 9 7.9 ± 1.6 scanning that depict the variations in scanning that reveal dimensional changes particularly interesting (Table 5). No C 93.5 ± 0.1 207 ± 1 322 ± 5 10.0 ± 0.2 dimensional change throughout the in camshaft bearing caps processed from influence of adding Zr in masteralloy Development, properties, volume of dog bone specimens (a) alloy A, (b) Alloy B, (c) Alloy C and (d) form on properties was observed. and applications for a Table 5 Data on apparent hardness and tensile properties of the alloys studied (Courtesy MPIF) (a) Alloy A, (b) Alloy B, and (c) Alloy C. the alloy used in commercial production of However, alloy C, with the zirconium high-thermal-conductivity (Courtesy MPIF) the part (AC2014) (Courtesy MPIF) addition in prealloyed form, showed Density sintered aluminium Dimensional Change modest increases in yield strength and Alloy Green Sintered (%) UTS, but a very significant increase in material g/cc % g/cc % OAL Width Length Spread elongation value to 10%. The paper presented by Richard L AC2014 2.47 88.8 2.46 88.6 +0.94 -1.01 -0.58 1.9 However, the most striking Hexemer Jr. (GKN Sinter Metals) on advantage of using prealloyed Zr behalf of his co-authors Ian Donaldson A 2.41 88.3 2.72 99.7 -3.80 -4.13 -2.47 1.7 was revealed, when the dimensional (GKN Sinter Metals) and Logan B 2.46 90.3 2.72 99.7 -3.29 -3.89 -2.37 1.5 changes in sintering of the three alloys Smith and Paul Bishop (Dalhousie C 2.45 89.9 2.72 99.7 -2.94 -3.84 -2.99 0.9 were assessed. University) focussed on the potential Direct measurements on sintered of PM aluminium products in thermal Table 6 Sintering response measured for the bearing caps processed from the three TRS bars (Table 4) indicated more management applications such as experimental alloys and the commercial system AC2014 (Courtesy MPIF) uniform shrinkages with alloy C heat sinks. Process/ Density Thermal Con- Mass or specific Thermal than with the other two alloys, but Material Heat sink applications represent Grade (g/cm3) ductivity (w/m-k) Conductivity the comparisons were shown even a large market for wrought and die TC / Density normalised more dramatically using a 3-D laser cast aluminium products, on the basis scanning technique. In the maps of a 3 to 4 cost advantage compared Aluminium Pure 2.7 247 91 1 derived from this technique, the extent with the primary competing material, Aluminium Die Cast A380 2.7 80-100 33 0.36 of dimensional change is indicated by copper. However, to date, this market Aluminium Extruded 6061 2.7 150 – 180 61 0.67 a colour coding. opportunity has not been tapped by PM The 3-D maps in Fig. 1 showed aluminium. Aluminium Extruded 6063 2.7 190 – 210 76 0.83 significant shrinkage variations Although aluminium cannot match Aluminium MIM 2.5 170 – 180 70 0.77 and warpage in Alloy A, marginal the thermal conductivity of copper per Copper Pure 8.9 398 45 0.49 improvements for Alloy B, but uniform se, the weight of a heat sink is often Wrought shrinkage (indicated by the uniform Copper 8.9 380 – 390 43 0.47 a design consideration and the 3 to 1 C11000 colour of the image) and absence of density advantage of aluminium over Copper Cast C81100 8.9 340 – 350 39 0.43 warpage for Alloy C. copper means that it can be highly To quantify these comparisons, competitive on the basis of specific Copper Cast C83400 8.7 180 – 190 21 0.23 information for a number of 2-D thermal conductivity. Copper MIM 8.5 320 – 330 38 0.42 sections of the bars was derived. Table 7 compares a range of Table 7 Thermal conductivities of selected aluminium and copper materials (Courtesy MPIF) These results (Fig. 2) emphasised aluminium and copper materials on the the exceptionally small dimensional basis of this parameter, which, in the deviations observed for Alloy C. Mass or specific Thermal final column, is normalised to denote Density Thermal Con- Material Process/Grade Conductivity These comparisons were further the value for pure aluminium as 1. (g/cm3) ductivity (w/m-k) TC / Density normalised confirmed on the basis of assessing In order to achieve a high thermal camshaft bearing cap parts, processed conductivity in sintered aluminium Aluminium Pure 2.7 247 91 1 at the GKN Sinter Metals Condover products, it was deemed to be neces- Copper Pure 8.9 398 45 0.49 plant from these experimental alloys. sary to minimise or eliminate porosity Commercial Very comparable results, to those (i.e. to achieve a sintered density as on laboratory-processed bars, were close as possible to full theoretical Aluminium PM ACT1-2014 2.6 144 55 0.60 derived from direct dimensional Fig. 2 Quantitative measurements of the Fig. 4 Quantitative measurements of the density) and to avoid those alloying Metal Matrix measurements (Table 6) and 3-D scan- maximum and minimum dimensional maximum and minimum dimensional additions that decrease TC. These Aluminium PM Al MMC1 2.7 137 51 0.56 ning (Figs. 3 and 4) and, in this case, change variations (mm) acquired for 9 change variations acquired from vertical criteria led the authors to concentrate the comparisons also included the New PM individual cross sections from sintered dog cross sections within camshaft bearing their interests on a simple Al-Mg-Sn standard commercial grade, AC-2014, bones fabricated from (a) Alloy A, (b) Alloy caps processed from (a) Alloy A, (b) Alloy press/sinter system. Aluminium PM TC2000-1.5 2.7 210 – 230 81 0.89 used for this bearing cap application. B, and (c) Alloy C. (d) 3D image illustrating B, (c) Alloy C and (d) AC2014 (Courtesy The studies of densification of Aluminium PM TC2000-1.0 2.7 240 - 250 90 0.99 It was concluded that this new alloy the locations of where cross sectional MPIF) a range of Al-Mg-Sn experimental development has potential benefits in Table 8 Thermal conductivities of existing and the newly developed aluminium PM alloys analyses were completed. (Courtesy MPIF) mixes, summarised in Fig. 5, led to the two areas: (Courtesy MPIF)

table demonstrate the superiority, w/o UTS Elongation Young’s Alloy Temper YS (MPa) in this context, of these alloys Sn (MPa) (%) (E) over established commercial PM Al-1.5Mg 0 T1 103 50 3.62 49.7 aluminium grades and, indeed, the PM Al-1.5Mg-0.1Sn 0.1 T1 103 47 4.44 46.3 TC2000-1.0 grade offers the same TC as pure aluminium. Al-1.5Mg-0.2Sn 0.2 T1 113 41 8.69 21.8 Two further property param- Al-1.5Mg-0.5Sn 0.5 T1 118 38 9.65 39.6 eters have been considered in this Al-1.5Mg-1.0Sn 1 T1 116 37 13.98 16.0 development: Al-1.5Mg-1.5Sn 1.5 T1 112 39 14.80 19.4 • Coefficient of thermal expansion (CTE) was measured for the new Al-1.5Mg-2.0Sn 2 T1 100 37 12.49 21.1 alloys and was found to be in line Table 9 Tensile properties of Al-1.5Mg-xSn systems (data extracted by the authors from with pure Al. Further, previous MacAskill et al) (Courtesy MPIF) work had shown that the level of this property could be lowered by AlN Addition UTS YS Elongation Young’s Matrix Alloy Temper the addition of ceramic materials (v/o) (MPa) (MPa) (%) (E) that have low CTE. Lower CTE is a 0 Al-1.5Mg-1.5Sn T1 112 39 14.80 19.4 desirable attribute for heat-sinks 2 Al-1.5Mg-1.5Sn T1 97 54 2.32 26.8 when matching with low expansion substrates such as silicon. 5 Al-1.5Mg-1.5Sn T1 108 57 2.63 45.0 • Tensile properties were measured 10 Al-1.5Mg-1.5Sn T1 121 62 4.49 31.5 on dog-bone test-pieces. These 15 Al-1.5Mg-1.5Sn T1 142 76 3.80 45.1 properties are presented in Table 9. 25 Al-1.5Mg-1.5Sn T1 92 90 0.40 40.7 Although, these properties are SiC Addition UTS YS Elongation Young’s Matrix Alloy Temper relatively low compared to estab- (v/o) (MPa) (MPa) (%) (E) lished PM aluminium alloys, they 0 Al-1.5Mg-1.5Sn T1 112 39 14.80 19.4 are considered to be sufficient for heat sink applications. However, the 2 Al-1.5Mg-1.5Sn T1 108 41 9.63 21.2 incorporation of ceramic additions 5 Al-1.5Mg-1.5Sn T1 108 47 6.66 23.9 was again considered to be a 10 Al-1.5Mg-1.5Sn T1 88 5 1 2.42 31.2 potential means of improving these Table 10 Influence of the addition of AlN and SiC on tensile properties of Al-1.5Mg-1.5Sn Fig. 5 Effects of Mg (a), Sn (b) and their combination (c) on the sintered density of aluminium PM compacts (data extracted by the authors mechanical properties. (Courtesy MPIF) from MacAskill et al) (Courtesy MPIF) The addition of ceramics in two forms was therefore studied – a sepa- gation but, given that the ceramic aluminium grades, with which to conclusions that: rate addition of silicon carbide (SiC) additions have intrinsically high attack this significant new market • Magnesium was more effective as or the in-situ formation of aluminium thermal conductivity compared with opportunity. an elemental addition than as a nitride (AlN) during sintering. aluminium, the authors have a high masteralloy. The results reported in Table 10 level of confidence that a beneficial demonstrate that additions of up to influence will also be observed in this Author • Two alloy compositions, 15% AlN bolster mechanical proper- context, provided that a good interface Al-1.5Mg-1.5Sn (wt %) and Dr David Whittaker. Dr Whittaker is ties while simultaneously reducing between the reinforcement and the Al-1.0Mg-1.0Sn (wt %) should be a consultant to the Powder Metal- CTE. matrix is created. selected for development. These lurgy and associated industries. The influence of these ceramic Overall, it can be concluded that two compositions were designated Contact +44 1902 338498 email: additions on thermal conductivity of this work has provided GKN Sinter as PM TC2000-1.5 and PM TC2000- [email protected] the new PM alloys is still under investi- Metals with a new suite of PM 1.0 respectively. Fig. 6 demonstrates that the first of these alloys provides thermal conductivity that is superior to the levels achievable with a range of standard ipmd.net wrought and die-cast aluminium materials. This figure also shows that, if elevated temperature thermal Register to receive our free conductivity is a significant design consideration, then this property can be further enhanced by the use of a weekly e-newsletter Zr-prealloyed Al as the base powder for the alloy. • PM Industry News • Conference reports The specific thermal conductivities of the newly developed alloys are • Technical articles ...... and more! Fig. 6 Thermal conductivities of selected aluminium PM, wrought and die cast materials. compared with those of existing (Courtesy MPIF) materials in Table 8. The data in this

Binder/lubricant developments enhance Powder Metallurgy part quality and strength

A presentation in the Special Interest Programme on Lubrication Science at the MPIF’s PowderMet 2012 Conference, June 10-13, Nashville, Tennessee from Francis Hanejko (Hoeganaes Corporation, USA), on behalf of his colleagues, William Tambussi and Jeanne Hooker, emphasised the message that the development of binder/lubricants has brought a range of compaction process control and dimensional control benefits, and has been an important enabler in the enhancement of product densities and strength levels through processes such as Warm Die Compaction. Dr David Whittaker reviews this paper exclusively for Powder Metallurgy Review/ipmd.net.

Traditionally, the PM structural parts this approach could do nothing about not totally dry, flow rate and apparent industry has had a love-hate relation- segregation and dusting problems density tended to change with time ship with pressing lubricants. They are associated with graphite and lubricant and also, generally, apparent density vital in terms of protecting compo- additions. Hence, binder treatments was reduced. nents and tooling during the forming and ejection processes, but can cause a range of process problems during “Traditionally, the PM structural sintering. PM’s initial approach to parts industry has had a love-hate pre-mixing, the simple mixing of relationship with pressing lubricants” elemental ingredients, was simple and cost effective but gave potential problems with segregation in mixes. were developed as a means of tackling These issues stimulated interest in the Next, diffusion alloying appeared these issues. use of polymer bonding (in Hoeganaes as an effective means of preventing Initially, oils were investigated as Corporation’s case, ANCORBOND® segregation of the metallic alloying a means of controlling dusting. This processing). The first generation of elements and improving control over was a simple approach but carried a such developments produced the dimensions and strength. However, number of disadvantages; mixes were targeted benefits of improved flow

Fig. 1 The effects of graphite and organic contents on Pore-Free Density (As presented at Fig. 2 Comparison of ejection characteristics of various lubrication systems (all PowderMet 2012, 10-13 June 2012, Nashville, compaction at 830 MPa) – Material FN-0205 (As presented at PowderMet 2012, 10-13 USA. Courtesy Hoeganaes) June 2012, Nashville, USA. Courtesy Hoeganaes)

44 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd © 2012 Inovar Communications Ltd Autumn/Fall 2012 Powder Metallurgy Review 45 Binder/Lubricants | contents | news | events | advertisers | contact | Subscription POWDER The low density additions of graphite and lubricant/ binder have particularly negative effects on PFD (Fig. 1). It Information METALLURGY was also observed that the practical limit of green density is around 98% of PFD (beyond this limit, formation of micro- laminations is likely) and, hence, the main potential route to Review higher green densities lay in raising PFD. Potential means of achieving this aim include: • Working with lower lubricant/binder levels • Raising compaction die temperature. One year PRINT subscription: £85 The development of further generations of binder/lubricants, often tailored for use in Warm Die Compaction, have contributed to and continue to contribute to furthering the • Price includes airmail shipping Note: Powder Metallurgy Review is also Fig. 3 Effect of temperature on green density. Material FLN2-4400 above objectives. • Published quarterly (4 issues) (As presented at PowderMet 2012, 10-13 June 2012, Nashville, The proprietary binder/lubricant, AncorMax 200, available free-of-charge in electronic format USA. Courtesy Hoeganaes) specifically developed for Warm Die Compaction at a tooling • Comprehensive coverage of the global PM industry temperature of around 93°C, is generally used at a 0.4 wt% addition level whereas a “new lube system” was revealed by the author, which is designed to be used at a level of only Your contact details 0.25 wt%. and for use at a tooling temperature of around 107°C. Title...... Forename...... Family Name...... Fig. 2 demonstrates that these binder/lubricants, used at these addition levels and tooling temperatures, provide Job Title/Position...... superior ejection properties to 0.75 wt% EBS in room temperature compaction and 0.4 wt% EBS in compaction at Organisation...... room temperature or at 97°C. Address ...... Work reported by several major powder suppliers has shown that the “real” green density increases as compaction ...... temperature increases and this is amply demonstrated by the Hoeganaes Corporation data in Fig. 3. Postcode...... Country...... Fig. 4 In-die density vs. compaction pressure. Material FLN2-4405 It has often been postulated that this effect is related to Tel: ...... Fax: ...... (As presented at PowderMet 2012, 10-13 June 2012, Nashville, a reduction of flow stress of the ferrous powder grade over USA. Courtesy Hoeganaes) E-mail: ...... this temperature range. However, it is clear that the use of a binder/lubricant, specifically designed to operate effectively at the increased temperature levels and used at lower Subscription period addition levels, must also be playing a significant role, as evidenced by the comparison between Figs. 4 and 5. Powder Metallurgy Review is published on a quarterly basis. The subscription fee for our print edition is £85.00 for one year In these figures, the powder mix used in cold compaction (four issues). Your subscription will commence with the next available issue unless otherwise stated below. contained 0.75 wt% Acrawax, whereas that used in Warm Please start subscription with issue: ...... Die Compaction contained only 0.4 wt% of a proprietary binder/lubricant. The two compressibility curves appear very different, when plotted in terms of green density in Fig. 4, Payment options but virtually coincide when plotted in terms of PFD in Fig. 5. Please invoice me. I understand that subscriptions will not start until full payment is made. The “new lubricant system” under development is particularly interesting in that it offers the potential, for the Please charge my credit card as follows: VISA MasterCard American Express first time, to lower the premix organic content to only 0.25 wt%. This allows PFD to be increased by 0.07 to 0.10 wt%. Fig. 5 In-die PFD vs compaction pressure. Material FLN2-4405 (As By employing a part ejection temperature of 107°C (225°F), Name on Card:...... presented at PowderMet 2012, 10-13 June 2012, Nashville, USA. it has been proved feasible, in laboratory pressing trials, Courtesy Hoeganaes) to achieve green densities of up to around 7.47 g/cm3 and Card Number:...... 3/4 Digit Security Code ...... limited prototype production has shown similar results. As Expiry Date:...... rates, reduced dusting and higher apparent densities, but, demonstrated in Fig. 2, this is accompanied by a reduction in because the binders were in addition to the normal pressing ejection forces. lubricants, the higher total organic content in mixes Limited work with a Double Press-Double Sinter process Signature:...... Date:...... restricted pore-free density and therefore achievable green at a high compaction pressure of 830 MPa has also shown density levels. that the generation of sintered densities over 7.6 g/cm3 is Or mail to: Inovar Communications Ltd The second generation of developments therefore feasible with this system. 2, The Rural Enterprise Centre concentrated on finding polymer additions that can deliver www.hoeganaes.com Fax to: +44 (0) 1743 469 909 Battlefield Enterprise Park both bonding and lubrication. Shrewsbury SY1 3FE, United Kingdom In early lubrication trials, it soon became apparent Email: [email protected] that maximum achievable green density was dependent Author: Dr David Whittaker. Dr Whittaker is a consultant to Tel: +44 (0)1743 454 990 on a parameter, referred to as Pore Free Density (PFD) the Powder Metallurgy and associated industries. Contact and defined as the density of a green compact if all of the +44 1902 338498 email: [email protected] porosity could be removed. Subscribe on-line at www.ipmd.net/pmreview

46 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd Advertisers & PM events | contents | news | events | advertisers | contact | 横浜 PM Events POWDER PM2012 METALLURGY “Challenge for the next generation” 2012 International Conference on Cemented Carbides September 12-16 Review PM2012 in Yokohama Japan Zhuzhou, China email: [email protected] Advanced technology and information for “Environment” and Advertisers’ index EuroPM2012 International Conference and Exhibition “Energy Saving” will be introduced. September 17-19 Ace Iron & Metal Co. 4 Basel, Switzerland www.epma.com Avure Technologies 25 Events Titanium 2012 Erowa 5 October 7-10 Global Review (JPMA, MPIF, EPMA President) Atlanta, Georgia, USA GEM Hi-Tech Co. Ltd. 13 Technical Program : Over 500 technical papers (Oral & Poster Sessions) www.titanium.org Haili Press 17 Powder Metallurgy World Congress & Exhibition PM2012 Special Interest Seminar & Special Session Includes October 14-18 Hoeganaes Corporation Inside Front Cover Exhibition : 147 Booths (15 Countries 93 Companies) Yokohama, Japan Höganäs AB Outside Back Cover www.pm2012.jp JPMA Special Seminar (Environment & JPMA Awards) ipmd.net PM e-newsletter 22 China 2012 PM Conference Opening Ceremony, Welcome Reception, Farewell Party, etc. November 8-10 Ipsen Inc. 2 Wuxi, China www.chinapm2012.com Lauffer Pressen 11 Hagen Symposium Lonza Inc. 15 PM related people in Japan are November 29-30 Makin Metal Powders 7 Hagen, Germany www.pulvermetallurgie.com MIM2013 38 looking forward to welcoming India 2012 PM Conference Nanjing East Precision Machinery Co.,Ltd. 18 December 13-15 New Delhi, India Orton Ceramics/Temp Tab 9 you in Yokohama. www.indiapm2012.com PM2012 World Congress Inside Back Cover 2013 Powder Injection Moulding International 44 PowderMet 2013 30 PM-13 International Conference and Exhibition Precision and Additive Manufacturing in Powder Metallurgy for Automotive and Engineering Industries February 7-9 Pune, India www.pmai.in MIM 2013 March 4-6 Orlando, USA www.mpif.org St Petersburg Technical Fair March 12-14 St Petersburg, Russia www.ptfair.ru Advertising

China PM Expo - International Powder Metallurgy To discuss advertising in Organized by Exhibition and Conference Powder Metallurgy Review April 26-28 Shanghai, China contact: Jon Craxford, www.cn-pmexpo.com Advertising Sales Director Tel: +44 207 1939 749 PowderMet 2013 International Conference on Powder Fax: +44 1242 291 482 Metallurgy & Particulate Materials Email: June 24–27 Chicago, USA [email protected] Important Information www.mpif.org Registration Late Registration August 2 – October 1, 2012 ▶▶▶ 48 Powder Metallurgy Review Autumn/Fall 2012 © 2012 Inovar Communications Ltd Further Information : www.pm2012.co.jp The future success for PM technology is to be found in the close interaction between application knowledge, design aspects, optimum process conditions and high-quality powder materials. Based on this notion we opened the door to our PoP Centre.

One example of how we extend the market for PM technology in the PoP Centre, is high load-carrying PM gears. We have already proven the concept and now advance our development activities even further.

Join us in the development of new powder based applications.