Powder Metallurgy Review Summer 2016 Vol 5 No 2

POWDER METALLURGY

VOL. 5 NO. 2 VOL. SUMMER 2016 REVIEW

COMPANY VISIT: SHW HIP AND HEAT TREATMENT PM-16 CONFERENCE REVIEW

Published by Inovar Communications Ltd ipmd.net PowderMetallurgy Review Summer 2016.pdf 1 4/24/16 10:42 PM

FACILITIES

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

The potential of powder metallurgy is only limited by one’s imagination… Hoeganaes Corporation, the world’s leader in the production of metal powders, has been the driving force behind the growth in the Powder Metallurgy industry for over 65 years. Hoeganaes has fueled that growth with successive waves of technology which have expanded the use of metal powders for a wide variety of applications. Hoeganaes Corporation production World Class site located in Bazhou City, Engineers and Hebei Province, China. Scientists at Hoeganaes’ new Innovation Center in the USA develop new products and processes that move the state of the industry forward, spanning Automotive applications to Additive Manufacturing. The Commencement of melting and atomization operations in Bazhou, China makes Hoeganaes Corporation the rst international-grade ferrous metal powder producer on the Chinese mainland. With production and mixing facilities across North America, Europe, and Asia, Hoeganaes serves our customers across the globe with the most advanced PM solutions.

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

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

Consulting Editor Dr David Whittaker Meeting the demands of Consultant, Wolverhampton, UK greater fuel efficiency and Production Hugo Ribeiro, Production Manager lower emissions Tel: +44 (0)1743 454990 Email: [email protected] Through lighter components and innovative design, Powder Accuracy of contents Metallurgy can contribute significantly to improving fuel Whilst every effort has been made to ensure the efficiency and reducing harmful emissions from the internal accuracy of the information in this publication, the publisher accepts no responsibility for combustion engine. errors or omissions or for any consequences arising there from. Inovar Communications Ltd One company that is committed to providing solutions that cannot be held responsible for views or claims expressed by contributors or advertisers, which contribute to the reduction of emissions is Germany’s SHW are not necessarily those of the publisher. Automotive GmbH. With its range of sintered products for engine and transmission applications SHW is a key Reproduction, storage and usage Single photocopies of articles may be made supplier to the global automotive industry. The company’s for personal use in accordance with national commitment to developing advanced Powder Metallurgy copyright laws. Permission of the publisher and products that help manufacturers meet and exceed payment of fees may be required for all other photocopying. ever increasing environmental regulations is key to its All rights reserved. Except as outlined above, success. We report on a visit to SHW’s PM facility in Aalen- no part of this publication may be reproduced, Wasseralfingen page( 37). stored in a retrieval system, or transmitted in any form or by any means, electronic, photocopying or otherwise, without prior In this issue we also present how the combination of permission of the publisher and copyright owner. Hot Isostatic Pressing and heat treatment in a single, integrated, process can offer numerous advantages, helping Submitting news and articles We welcome contributions from both industry reduce energy consumption and improve the delivery time and academia and are always interested to hear for components that require both processes. Continued about company news, innovative applications improvements in HIP equipment and a breakthrough in gas for PM, technology developments, research and more. quenching at HIP pressures is providing a dramatic boost in Please contact Paul Whittaker, Editor what an integrated HIP and heat treat process can deliver. Tel: +44 (0)1743 454992 Dr Stephen J Mashl reports on the state of this game- Email: [email protected] changing development (page 45).

Subscriptions Powder Metallurgy Review is published on a We also report on the recent PM-16 International quarterly basis. It is available as a free electronic Conference & Exhibition on Powder Metallurgy organised publication or as a paid print subscription. The by the Powder Metallurgy Association of India in February. annual subscription charge is £85.00 including shipping. A number of interesting papers are highlighted from the diverse technical programme (page 57). Advertising opportunities Contact Jon Craxford, Advertising Director, to discuss how we can help promote your products Paul Whittaker and brand, both online and in print. Editor, Powder Metallurgy Review Tel: +44 (0) 207 1939 749 Fax: +44 (0) 1743 469 909 Email: [email protected]

Design and production Inovar Communications Ltd. ISSN 2050-9693 (Print edition) ISSN 2050-9707 (Online edition) Cover image © 2016 Inovar Communications Ltd. Powder Metallurgy camshaft This magazine is also available for free adjustment part with densified download from www.ipmd.net surface (Courtesy SHW) ipmd.net© 2016 Inovar Communications Ltd Summer 2016 Powder Metallurgy Review 1 Worldwide Global manufacturer of nodular and spherical aluminum powders, pre-alloyed aluminum powders, and aluminum premixes for PM www.ampal-inc.com www.poudres-hermillon.com

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

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

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

20 39 42 47 70

in this issue

37 SHW Automotive: A global supplier 57 Powder Metallurgy in India: New of gear pump and camshaft phaser applications for metal powders at components PM-16 SHW Automotive GmbH is a specialist The PM-16 International Conference and manufacturer of sintered components for Exhibition on Powder Metallurgy and engines and transmissions and is recognised Particulate Materials, along with the 42nd as a leading supplier of automotive pumps. Dr Annual Technical Meeting of the Powder Georg Schlieper recently visited SHW’s Powder Metallurgy Association of India (PMAI), took Metallurgy plant in Aalen-Wasseralfingen and place in Pune, India. In his report for Powder reports on the company’s activities for Powder Metallurgy Review, Professor Ramamohan Metallurgy Review. Tallapragada provides an overview of the conference and highlights new applications for metal powder technology discussed at 45 Combining Hot Isostatic Pressing and the event. heat treatment in a single process: An elegant way to streamline the supply chain The combinination of HIP and heat treatment in a single process offers end-users an regular features evefective way to streamline the supply chain. It reduces shipping and handling 4 Industry news costs, decreases energy consumption and Worldwide 72 Advertisers’ index Global manufacturer of nodular and spherical aluminum powders, improves the delivery time for metal parts pre-alloyed aluminum powders, and aluminum premixes for PM that require both HIP and heat treatment. 72 Events guide Recent developments are providing a dramatic www.ampal-inc.com www.poudres-hermillon.com boost to what an integrated HIP and heat In the Americas treat process can deliver. Dr Stephen J Mashl Supplier of carbonyl iron and atomized stainless steel powders for reports on the state of this game-changing development. the PM and MIM industries

United States Metal Powders, Incorporated 408 U.S. Highway 202, Flemington, New Jersey 08822 USA Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 email: [email protected] © 2016 Inovar Communications Ltd Summer 2016 Powder Metallurgy Review 3

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

Hoeganaes Corporation begins production of metal powder in China

Hoeganaes, part of GKN Powder GKN Hoeganaes international Metallurgy, is starting production grade powders for use in automo- of high quality automotive grade tive and industrial applications in powders in China for the Asian the growing Asian markets. These market. The new joint venture powders enhance the manufac- Representatives of GKN Powder further expands GKN Powder turers’ ability to achieve more Metallurgy and Bazhou Hongsheng Metallurgy’s footprint in China and complex geometries, improved Industrial Company Ltd during makes Hoeganaes the only atom- dynamic properties and ultimately the opening ceremony (Courtesy ised iron powder manufacturer with produce lighter weight components. Hoeganaes Corporation) complete production facilities in “For the first time this joint the world’s three major automotive venture will provide a local manu- producing regions. facturing base for GKN’s advanced to expanding our global footprint The agreement with Chinese metal powder technologies, and meeting the needs of our partner Bazhou Hongsheng enabling us to meet the increasing customers.” Industrial Company Ltd sees GKN need for more technically enhanced Hoeganaes is one of the world’s Powder Metallurgy taking a majority powders in Asia,” stated Peter largest manufacturers of metal share in a manufacturing facility Oberparleiter, CEO GKN Powder powder, the essential raw mate- located in Bazhou City, Hebei Metallurgy. rial for Powder Metallurgy, with Province, China. “It will allow us to better serve manufacturing facilities in the United The 24,600m2 plant has been our customers in both China and States, Europe and Asia. in operation since 2009 and will the wider Asia Pacific area and is www.hoeganaes.com expand its product line to produce a reflection of our commitment

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Ampal expands its aluminium Plansee to expand powder production facility production in

Ampal, Inc., a wholly owned subsid- ington. The team has developed South Korea iary of United States Metal Powders, aluminium alloy powders for new and Plansee has announced it is Inc. (USMP), formerly United States advanced technologies such as Metal expanding production capacity in Bronze Powders, Inc. (USBP), has Injection Moulding (MIM) and Additive South Korea following a ground- announced the expansion of its Manufacturing (AM). breaking ceremony for the construc- aluminium powder production facility Once completed, the expansion is tion of a new factory in Dongtan. The A Global Leader in Water & in Palmerton, Pennsylvania, along expected to create fifteen new jobs site is said to be close to a number with the acquisition of an adjacent for a total employment at Ampal of of the company’s important key Gas Atomized Metal Powders industrial property. over forty people. “After operating customers and is due to start opera- Ampal was founded in 1968 and successfully for more than three tion at the end of 2016. & HDH Based Titanium Powders its parent company, USBP, in 1918. decades in Palmerton, PA, this Plansee stated that it is investing Ampal moved its production facility expansion provides an opportunity to ten million euros in the project. The For Press & Sinter, Metal Injection Molding and from Flemington, New Jersey to its create new job opportunities and to company plans to bring its existing current location in 1982 and has been continue to drive our growth in the production and sales sites in Korea Spray Coating applications ranging from Aerospace operating in Palmerton for the last 34 aluminium powder business. We are under one roof at the new facility. to Automotive, and Tool Steels to Medical Products, years. The company has grown to be proud of our team of highly talented “Above all, it is our customers the largest US producer of aluminium employees at Ampal today,” stated in the display and semiconductor depend on AMETEK Specialty Metal Products. Our powder. K Clive Ramsey, President of Ampal industries that will benefit from the ability to provide custom powders that meet your The newly purchased industrial and its parent company, USMP. “We increased capacity. The construction property will facilitate the company’s look forward to continuing our strong of our own facilities underscores our exact specifications makes us your ideal supplier. expansion by providing warehouse ties to the local community and are long-term commitment to Korea,” space and a new location for its pleased to be creating new employ- stated Bernhard Schretter, member Whether you need large or small batches, our Research and Development team ment opportunities.” of the Board of Directors at Plansee. which will be relocated from Flem- www.ampal-inc.com www.plansee.com proprietary manufacturing methods allow us to meet the most demanding and comprehensive specifications.

Innovative & Advanced Metallurgical Technology

1085 Route 519 Eighty Four, PA 15330 USA Tel: +1 724-250-5182 • Fax: +1 724-225-6622 Email: [email protected] www.ametekmetals.com

Metaldyne Performance Group Kyocera acquires reports profit up 6% during Q1 SGS Tool

Metaldyne Performance Group Inc. are looking forward to a successful Japan’s Kyocera Corporation has has reported net sales of $739.5 year in 2016.” announced that has acquired 100% million for the first quarter 2016, Metaldyne Performance Group ownership of US based SGS Tool compared to $765.2 million in Q1 is a provider of highly-engineered Company. The company, located in 2015. Gross profit, however, was components for use in powertrain Munroe Falls, Ohio, will be renamed reported at $136.5 million for the and safety-critical platforms for Kyocera SGS Precision Tools, Inc. quarter, an increase of 6% from Q1 the global light, commercial and Kyocera Corp. is the parent and 2015. industrial vehicle markets. The global headquarters of the Kyocera Commenting on the company’s company’s metal-forming manufac- Group and was founded in 1959 results, George Thanopoulos, Chief turing technologies and processes as a producer of fine ceramics. Executive Officer of MPG, stated include aluminium die casting, Since combining these engineered “We are extremely pleased with our forging, iron casting, Powder Metal- materials with metals and integrating first quarter results. Expansion® of lurgy and Metal Injection Moulding them with other technologies, Keystoneour margins and continued strong Powdered as well as advanced machining Metal and Kyocera Company has become a leading EBITDA despite certain macro assembly. supplier of cutting tools, industrial headwinds show the strength in Headquartered in Southfield, ceramics, solar power generating our business. Our solid cash flow Michigan, Metaldyne Performance systems, mobile phones, printers, gave us flexibility to increase our Group has a global footprint span- copiers, electronic components and dividend, start our share repurchase ning 60 locations in 13 countries semiconductor packages. During program and build cash on the across North America, South the year ended March 31, 2015, the balance sheet. We are continuing to America, Europe and Asia with company’s net sales totalled around win new business and focus on fast approximately 12,000 employees. $12.7 billion. growing powertrain applications. We www.mpgdriven.com www.global.kyocera.com

Raising the potential for powdered metal applications

MPIF 2015 MPIF 2014 Driven by GRAND GRAND PRIZE PRIZE innovative thinking, AWARD AWARD Keystone has a solid reputation for bringing industry firsts to market.

Join us in pioneering the next leap forward for powdered metal manufacturing.

www.keystonepm.com Keystone Powdered Metal Company | 251 State Street | St. Marys, PA 15857-1697 | Phone 814-781-1591 Email: [email protected]

8 Powder Metallurgy Review Summer 2016 © 2016 Inovar Communications Ltd ELNIK takes the gamble out of ELNIK takes the gamble out of ELNIKbuyingELNIK takes takesMIM debindthethe gamblegamble and sinter out ofof buying MIM debind and sinter buyingequipmentbuying MIM MIM with debinddebind the helpandand sinterof equipment with the help of equipmentDSHequipment Technologies! withwith thethe helphelp of DSH Technologies! Elnik provides FREE TRIAL RUNSDSHDSH BEFORE Technologies! Technologies! YOU PURCHASE OUR EQUIPMENT Elnik providesto FREE prove TRIAL how cost-efficientRUNS BEFORE our YOU technology PURCHASE can beOUR EQUIPMENT ElnikElnik provides provides toFREE FREEprove TRIAL TRIAL how RUNS cost-efficientRUNSELNIK BEFORE BEFORE takes YOU ourYOU technologyPURCHASE PURCHASEthe gamble can OUROUR be EQUIPMENT out of Wasted MIM production runs resulting in “half-baked” parts can cost you thousands $$! 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material flow and capacity, working closely with our Metal Powder Products customers to meet and exceed their requirements.” acquired by Millstein & Co Metal Powder Products experienced a record year in 2015 and is well positioned to capitalise on market Metal Powder Products, headquartered in Westfield, trends. “We are impressed by Metal Powder Products’ Indiana, USA, has announced that it has been acquired strong track record of innovation under the leadership by Millstein & Co., a diversified investment management of Ben James and his team of skilled professionals. The and financial services firm. Metal Powder Products company’s powder metal expertise has enabled it to has three production facilities based in Pennsylvania deliver dynamic growth and we see great future potential and specialises in the production of Powder Metallurgy driven by the company’s market-leading aluminium components, including custom-engineered gears and capabilities. We look forward to working with Ben and sprockets, complex structural parts, high strength his team to advance Metal Powder Products’ business,” aluminium parts and components for use in high stress, stated Michael Duran, a Partner at Millstein & Co. wear and magnetic applications. It was announced that existing Metal Powder Products The Millstein team has extensive experience owning executives have also made equity investments into the and operating industrial companies and manufacturing company, becoming minority shareholders. “The invest- businesses similar to Metal Powder Products. Metal ment from Millstein & Co. strengthens Metal Powder Powder Products was formerly a subsidiary of Revere Products’ position for continued growth as a leading Industries, a leading manufacturer of high-performance supplier of innovative, custom-engineered products in the metal and plastic components based in Indiana. powder metal industry,” stated Ben James, President of “Metal Powder Products’ three factories in Penn- Metal Powder Products. “My team is extremely excited sylvania produce excellent quality products that delight for the opportunity to work with Millstein & Co. and I am customers,” stated Millstein & Co. Operating Partner confident that together we can successfully build on the Chuck Spears. “We are impressed with the teamwork scalable growth of our business.” and productivity of the workforce as they strive for www.metalpowder.com excellence. We plan further investments in automation, EPSI_93x132:Layout 1 09.09.2011 14:20 Uhr Seite 1 New MPIF Standard 35 Materials Standard Released

The Metal Powder Industries Federation has announced that the 2016 edition of MPIF Standard 35, Materials Isostatic Presses Standards for PM Structural Parts, has been released. ProductionCIP: dia 1m,200 MPa ProductionHIP:2000°C,200MPa The Standard provides the design and materials engineer with the latest engineering property data and information available in order to specify materials for structural parts made using the PM process. Revised and expanded, this new edition was developed by the Powder Metallurgy commercial parts manufacturing industry. Each section of the Standard is clearly distinguished by easy to read data tables and explanatory information for each material listed. Detailed notes and definitions, along with data cited in both Inch–Pound and SI units, help to make the standard more user friendly. The updated publication does not apply to materials for Engineered Pressure Systems Int. N.V. PM self-lubricating bearings, Powder Forged (PF) or Metal Walgoedstraat 19, B 9140 Temse, Belgium Injection Moulded (MIM) products which are covered in Tel : +32 (0)3 711 64 24 separate editions of MPIF Standard 35. The next edition of [email protected] www.epsi-highpressure.com MPIF Standard 35 Materials Standards for Metal Injection For customers in North America, please contact : Molded Parts is due to be published shortly. EPSI-Haverhill, MA Tel : + 1 978 469 82 80 www.mpif.org

AMG boosted by Summerev Hard Materials meeting to sales of Powder take place at Hilti

Metallurgy The EPMA’s European Hard Mate- parameters on elevated temperature induction furnaces rials Group will be holding its properties. It is intended that inter- Summerev 16 meeting at Hilti AG, faces can be interpreted at both the AMG Advanced Metallurgical Group Liechtenstein, June 16-17, 2016. microscopic scale (interphase) and N.V., headquartered in Amsterdam, Summerev 16 will focus on the mesoscopic (coatings, substrates, The Netherlands, has reported characterisation of interfaces and etc) and elevated does not just mean a 4% increase in group earnings associated chemistry and phase very high temperatures but also during the first quarter 2016. AMG metrology of substrates and adjacent intermediate, around 600-800°C. stated that EBITDA (earnings before matrices, with additional presen- www.epma.com interest, taxes, depreciation and tations on the influence of these amortisation) totalled $21.2 million in Q1 2016, up from $20.4 million in Q1 2015. Net income attributable to shareholders increased to $12.0 million in the first quarter 2016 from $2.7 million in the Q1 2015. AMG Engineering achieved EBITDA of $4.6 million during the first quarter 2016, a 49% increase from $3.1 million in Q1 2015. The Engineering division was reported to be continuing to experience strong demand in the areas of plasma re-melting furnaces for the aerospace market and induction furnaces for Powder Metallurgy applications. POWDERMET 2016 AMG Critical Materials generated Boston, USA / 5-8 June EBITDA of $16.5 million during the Visit us at Booth #115 first quarter 2016, a 4% decrease compared to the first quarter of 2015. Year-over-year double-digit declines in average quarterly prices for all key products resulted in a 13% reduction in revenues in the first quarter 2016 compared to the first quarter 2015, the company stated. “AMG earnings for the first quarter were strong despite PM Tooling System continued year-over-year weakness in metal prices. AMG did experience The EROWA PM tooling system is the standard a modest improvement in select metal prices compared to the interface of the press tools between the fourth quarter 2015. AMG’s focus toolshop and the powder press machine. on operational excellence and price risk management has resulted in Its unrivalled resetting time also enables solid financial results under difficult you to produce small series proﬁ tably. market conditions,” stated Dr Heinz Schimmelbusch, Chairman of the www.erowa.com Management Board and CEO. www.amg-nv.com

identified as non-strategic operations and will remain in Sandvik reorganises Sandvik Venture, now to be labelled ‘other operations’. The business areas and identifies company announced that it plans to exit from these businesses, although the process is yet to be initiated. non-strategic operations “By consolidating operations we will achieve total ownership and accountability for the respective businesses, aiming Sandvik has announced plans to reorganise and to improve the long term efficiency in Sandvik,” stated Björn consolidate its operations in the Sandvik Venture busi- Rosengren, Sandvik’s President and CEO. ness area. The new structure, effective July 1, 2016, will “For Sandvik Machining Solutions the structural change see the Sandvik Venture business area and manage- is driven by achieving total ownership of the supply chain ment team dissolved, with Jim Nixon, current President and strengthening the position in the round tools segment. of Sandvik Venture, leaving the company. For Sandvik Mining and Rock Technology we consolidate The restructuring will include moving Wolfram the similar product offering of Rock Tools and Drilling and (Wolfram Bergbau und Hütten) and two selected Completions under the same umbrella. Over time we will production sites from Sandvik Hyperion into the Sandvik exit from the businesses now reported in other operations, Machining Solutions business area. These businesses making Sandvik even more focused on its core businesses,” are internal suppliers to Sandvik Machining Solutions. added Rosengren. The selected production sites in Sandvik Hyperion www.sandvik.com supply metal powder and develop round tool blanks. Sandvik Drilling and Completions (Varel) will move into the Sandvik Mining and Rock Technology business Kennametal announces fiscal area. The product offering comprises consumables such as drill bits and down-the-hole products for the oil 2016 third quarter results and gas and mining industries. Sandvik announced that Sandvik Process Systems Kennametal Inc. has reported mixed results for the 2016 and Sandvik Hyperion, excluding the two sites to be fiscal third quarter ended March 31, 2016. Sales were $498 merged into Sandvik Machining Solutions, have been million, compared with $639 million in the same quarter last year. Sales decreased by 22%, reflecting a 10% decline due to divestiture, an 8% organic decline and a 4% unfavourable currency exchange impact. AMERICAN ISOSTATIC PRESSES, INC. Operating income was $27 million, compared with an The HIP Industry Innovators operating loss of $120 million in the same quarter last year. Adjusted operating income was $39 million, compared with * HIP - Hot Isostatic Presses $56 million a year ago. Kennametal stated that the decrease * CIP - Cold Isostatic Presses in adjusted operating results was driven primarily by organic * Temperatures to 2200 C * Pressures to 700 MPa sales decline, unfavourable mix, lower fixed cost absorption * Thermocouple Sales and unfavourable currency exchange, offset partially by lower * New and Used Systems raw material costs and restructuring benefits. Adjusted operating margin was 7.8% in the current period and 8.8% in the prior year period. “Kennametal’s third quarter performance reflects progress from operating results in a challenging environment, and benefited from a favourable tax rate,” said Ron De Feo, Kennametal President and CEO. “Infrastructure made progress, posting adjusted operating income of $10 million compared with losses for the first half of the year, and Industrial results reflect better sequential margins as well with adjusted operating income of $30 million. Adjusted EPS, while still lower year-over-year, strengthened sequentially as a result of the higher gross margins and lower operating expenses.” “We have a lot of improvement opportunities within Kennametal to simplify operations, lower costs and drive margin improvements over time. We need to be more customer responsive and grow market share with innovation, 1205 S. Columbus Airport Road entrepreneurship and speed - all things we are working on Columbus, Ohio 43207 and plan to discuss with the investment community in the AIP PH: 16144973148 future,” De Feo continued. FX: 16144973407 www.aiphip.com www.kennametal.com

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SACMI is an Italian Group that leads the world in the design, production and supply of industrial technologies and systems. It specializes in machines and complete plants for the ceramics, beverage & packaging, food processing, inspection systems, and metal powder industries. The SACMI GROUP is present in over 30 countries worldwide with a total of over 90 companies. With 95 years of experience as an equipment supplier, more recently SACMI has introduced a wide range of new equipment and technology for the METAL POWDER INDUSTRY by making the most of synergies between the many specialized companies in the Group and relying on a worldwide network of after sales service centres.

www.powdermetalpresses.com We know what makes Hard Metals Meeting the highest standards for drying and powder quality

A GEA spray drying plant unites innovation and size distribution, residual moisture content, experience to state-of-the art process technology bulk density, particle morphology and other for the production of hard metals and advanced requirements. At the same time, all GEA plants ceramics. We have pioneered this technology, are designed to meet the strictest requirements and our expertise helps you meet the highest regarding eﬃ ciency, health and safety and standards of powder quality, including powder environmental compliance. | contents page | news | events | advertisers’ index | email | Industry News

Miba announces record Call for Papers issued capital expenditure of over for the 19th Plansee €110 million Seminar 2017

Miba AG has reported that consolidated revenue climbed A Call for Papers has been issued by 7% to €719.1 million in its last fiscal year (February 1, by organisers of the 19th Plansee 2015, to January 31, 2016). Investments in property, plant Seminar, the International and equipment reached a new all-time high of almost Conference on Refractory Metals €80 million and those in research and development a and Hard Materials, taking place record €31.8 million. The number of employees also at the headquarters of the Plansee continued to rise. As of January 31, 2016, Miba had 5,397 Group in Reutte, Austria, from May members of staff working at 22 sites worldwide. 29 – June 2, 2017. The past fiscal year showed Miba’s main fields to be Authors are invited to submit running at two different speeds. While the automotive abstracts for papers to be presented industry performed strongly, as it had done in the in either lecture or poster format. All papers must previous year, Miba faced weak to downward trends contain unpublished results that are of current interest in segments of the capital goods market. “The past and abstracts should clearly outline the aim of the fiscal year has proven once again how important our work and the methods employed, as well as the major diversified business model is, especially in volatile times, results and conclusions. The deadline for submission of and that flexibility and continuous development are the abstracts is September 9, 2016. watchwords,” said CEO F. Peter Mitterbauer. The presentations at the Plansee Seminar will include Global demand for construction machinery, mining all areas where products based on Refractory Metals and equipment and ships fell again in 2015. The truck market Hard Materials play an important role, or where they are turned in a satisfactory performance in the US and promising alternatives to present material solutions. Europe, but in China declined sharply, particularly from www.plansee-seminar.com the second half of the year onwards. The markets for tractors and locomotive applications were on a stable trend, while demand for power electronics components for energy transmission showed a slightly positive trend. Miba is an important partner to all renowned manufacturers in the above market segments with its development and production of engine bearings, sintered components, friction materials, coatings, power electronics components and special machinery. Consolidated revenue climbed by EUR 49.8 million year on year to EUR 719.1 million. Earnings We know what makes before interest and tax (EBIT) amounted to EUR 82.9 million (2014/2015: EUR 81.9 million). “The Hard Metals earnings performance reflects the challenging market environment,” Mitterbauer explained. Miba stated that it intends to grow organically and Meeting the highest standards for drying and powder quality through acquisitions. “In addition to expanding our established lines of business, we also intend to broaden our product portfolio through acquisitions. With our A GEA spray drying plant unites innovation and size distribution, residual moisture content, expertise in technologically sophisticated components, experience to state-of-the art process technology bulk density, particle morphology and other we are also able to create added value in other areas around the megatrends mobility and energy efficiency,” for the production of hard metals and advanced requirements. At the same time, all GEA plants Mitterbauer added. ceramics. We have pioneered this technology, are designed to meet the strictest requirements “The dynamic environment we are operating in at Suppliers of metal powders to the PM Industry and our expertise helps you meet the highest regarding eﬃ ciency, health and safety and present and rapid technological progress demand an since 1945 standards of powder quality, including powder environmental compliance. even sharper focus on innovation and technology. Only in this way can we offset any sustained market weakness Ronald Britton Ltd, through an appropriate increase in new product launches Regent Mill, Regent Street, and thus continue to extend our technology and product Rochdale, United Kingdom Tel: leadership,” Mitterbauer concluded. +44 (0)1706 666 620 Cert No. 9125 ISOCert. 9001, No. ISO 9125 14001 web: ISO 9001 ISO 14001 www.miba.com www.ronaldbritton.co.uk

New vibratory sieve shakers aim to Höganäs adds make sieve analysis more convenient 17-4 stainless steel to its AM Retsch GmbH, Haan, Germany, has announced a new generation of its range vibratory sieve shakers. The new sieve shakers are claimed to offer Sweden’s Höganäs AB has extended easy and convenient operation, the range of materials suited to its ensuring accurate, reliable and Digital Metal® Additive Manufacturing user-friendly grain size analysis. The technology by including high Retsch AS 200 and AS 300 vibratory performance 17-4 PH stainless steel. sieve shakers also include optimised According to Höganäs, 17-4 PH control and vibration decoupling, enables production of components resulting in the machines running with high strength and hardness. very quietly. The material is a hardening Improvements to the model range grade exhibiting considerably higher include the updating of the entry- model AS 200 control has been strength compared to the more level modelmodel, AS AS 200 200 basic basic, to to include include further optimised and can now be commonly used austenitic 316L. It digital control, a standard feature on equipped with up to ten sieves. New also provides improved corrosion other models in the AS 200 series. features include the storage of up to resistance compared to 400 series Parameters such as performance 99 sieving programs as well as USB ferritic stainless steels. and time are now visible on the connection for use of EasySieve® Digital Metal is a 3D metal printing display. evaluation software. The AS 300 technology enabling production The AS 200 digit cA model now control for sieves with a 300 mm of small and complex objects that operates with controlled amplitude diameter is now also available in the would be costly, if not impossible, to which is indicated in the display, just new design. produce using traditional methods. like the sieving time. The high-end www.retsch.com www.hoganas.com

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Performance Ingredients Functional Chemicals Carpenter Technology reports third quarter results Metal Powder Lubricants

Carpenter Technology Corporation has announced financial results for the quarter ended March 31, 2016, in which the company reported a net loss of $23.9 million. Net sales for the third quarter of fiscal year 2016 were $456.3 million. Net sales excluding surcharge were $402.4 million, a decrease of $60.5 million (or 13%) from the same quarter last year, on 11% lower volume. The operating loss was $24.3 million, a decrease of $29.1 million from the third quarter of the prior year. The operating loss included $54.7 million in primarily non-cash impairment charges related to certain assets in the company’s oil and gas businesses within the Performance Engineered Products (PEP) segment as well as other special items. Operating income, excluding pension earnings, interest and deferrals (EID) and special items, was $35.2 million, compared to $35.1 million in the prior year period. These results primarily reflect lower volume, offset by an improved product mix and lower operating costs compared to the same period one year ago, the company stated. During the quarter, the company experienced growth as expected across the Aerospace & Defence, Medical and Industrial & Consumer end-use markets Acrawax® C Lubricant on a sequential basis. The Energy end-use market was also higher driven by strong performance in the Setting the standard in the metal powder industry, Acrawax® Power Generation sub-segment, while the Oil and Gas C Lubricant is a clean-burning, metal free lubricant that does sub-segment was down significantly on a sequential not generate metallic or corrosive byproducts. Acrawax® basis. C Lubricant is combustible, leaving no residue on sintered “Despite challenging conditions, we continue to parts. believe the Energy end-use market is strategically important given our strong customer relationships and the value our material solutions bring to Acrawax® C Lubricant Offers: demanding applications that require high strength and corrosion resistant products,” stated Tony Thene, – Precise particle size control Carpenter’s President and Chief Executive Officer. – Free flowing powder mixes Free cash flow in the third quarter of fiscal year – Low die wear and easy part removal from the die 2016 was $47 million, compared to $87 million in the same quarter last year. Capital expenditures in the – Reduced part distortion third quarter of fiscal year 2016 were $16.6 million, – Variety of custom particle sizes compared to $24.8 million in the prior year’s third quarter. For the full year, Carpenter continues to expect inventory to decline in the fourth quarter and finish largely in-line with year-end fiscal 2015 levels. The Company now expects capital expenditures to be approximately $85 million to $95 million for fiscal year 2016, versus prior guidance of $100 million. www.cartech.com Contact us to learn more: E: [email protected] T: + 1 201 316 9200 www.lonza.com

Federal-Mogul’s Powertrain division reported first quarter Federal-Mogul reports revenue of $1,128 million, compared to $1,138 million in the increased sales in first same prior year period. The slight decrease in Powertrain’s revenue was principally driven by a $30 million negative quarter 2016 impact from currency exchange rate fluctuations and a $13 million decrease in inter-segment sales, partially offset by Federal-Mogul Holdings Corporation has announced revenue from the acquired valvetrain business. financial results for the first quarter ended March 31, Federal-Mogul’s Motorparts division reported first 2016, stating that net sales for the first quarter were quarter revenue of $831 million, compared to $773 million $1,897 million, compared to $1,835 million in Q1 2015, a in the prior year period. Revenue growth of $80 million $62 million or 3% increase. was partially offset by a $22 million negative impact from Aftermarket sales growth in the US and Canada as currency exchange rate fluctuations. well as sales from the acquired valvetrain business, www.federalmogul.com were partially offset by $52 million of negative impact from currency exchange rate fluctuations. Gross profit was $288 million, or 15.2% of sales, a 1.5 percentage point margin improvement, compared with Q1 2015. The improved gross profit margin was driven HC Starck joins Worcester primarily by higher aftermarket sales in the US and Canada, operational improvements in both divisions as Polytechnic Institute’s Center well as the favourable impact of ongoing restructuring for Heat Treating Excellence and integration programs. Net income from continuing operations attributable to Federal-Mogul in the quarter HC Starck has announced it is to partner with the Worcester was $35 million, compared with a net loss from Polytechnic Institute (WPI) Center for Heat Treating continuing operations attributable to Federal-Mogul of Excellence (CHTE), based in Worcester, Massachusetts, $11 million in Q1 2015. Adjusted net income in Q1 2016 USA. The CHTE is an alliance between the industrial sector was $52 million and operational EBITDA in Q1 2016 was and university researchers that addresses short and long- $193 million, compared to $142 million in Q1 2015. term needs in the heat treating and thermal processing industry. ”We are very excited to join the team at WPI Center for Heat Treating Excellence,” stated Dmitry Shashkov, Member of HC Starck’s Executive Board and Head of the PRECISION Fabricated Products Division. “With our commitment to quality and technological expertise, we work side-by-side PERFORMANCE Engineering with our customers to ensure they have the highest quality Materials product. We are also rapidly growing our business to PRODUCTIVITY match the demands of the global marketplace, working with OEM and aftermarket furnace manufacturers on their PRICE new designs. To match this growth, HC Starck has made significant investments in our fabrication capabilities and we are leading the development of new materials for high

In other words: tight Dimensional Control, high Mechanical temperature applications to improve cost and performance Performance, fast and consistent Flowability, Cost Competitiveness for our customers.” versus other materials and manufacturing technologies. We at IMERYS Graphite and Carbon address the 4 P’s of Powder HC Starck’s product portfolio includes boats, trays, Metallurgy and Hard Metals by presenting tailor made offerings heating elements, thermal shields, hot zones, furnace to the Market. Our portfolio of Carbon Solutions consists of High Purity Synthetic Graphite, Highly Conductive Carbon Black and racks and assemblies. The company added that its Natural Flake Graphite (processed from our 100% owned Canadian team of research engineers are continually developing mine, located in Lac-des-Îles, Quebec). We remain committed to the key characteristics of Purity and Oversize Control. new materials for high temperature vacuum and inert atmosphere furnaces for industrial processes such as annealing, brazing, heat treating, HIP, melting, pre-heating, powder processing, sintering, tempering and MIM. These innovative materials help improve furnace cycle time, maintain temperature uniformity and reduce carbon contamination. The benefits for customers include less component rejections, better handling and reduced production cost compared to graphite and ceramics. www.hcstarck.com www.wpi.edu

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Ultrafine gas atomised powders available from Atomising Systems

Atomising Systems Limited, these upgrades ASL states that it Sheffield, UK, has announced that has more than doubled its production significant research and development capacity for the finest grades. work has been undertaken on its It was announced that the gas atomiser systems to address the company’s quality control laboratory increasing market for ultrafine gas has also received a significant boost atomised powders. Following work with a new Malvern Mastersizer, to improve the tundish system, the a total oxygen determination 200 kg batch capacity gas atomiser instrument, a compaction press and Gas atomising at Atomising Systems has now been upgraded with a high tensometer for green determination Limited power gas heater allowing much of water atomised powders and an higher atomising gas temperatures XRF chemical analyser. All are now and thermal spray processes to be achieved. in operation, assuring the quality amongst others. These investments Coupled with extensive work on and consistency of the ultrafine gas are already proving to be extremely ASL’s gas atomising nozzle system, atomised powders. beneficial,” stated Simon Dunkley, the upgrades enables the production “While a massive increase in ASL’s Managing Director. of stainless steels with a median orders for water atomised powders “This QC laboratory investment particle size of less than 20 microns. has kept us very busy, we have not of well over £200,000, coupled with Further investment in uprated sieving neglected to develop our capability the recruitment of extra laboratory and classification systems also to serve our gas atomised powder staff, ensures ASL can provide a QC allows ASL to undertake powder clients with new grades for Metal service exceeding that expected of separations from over 100 microns Injection Moulding, Additive our demanding clients.” down to less than 5 microns. With Manufacturing, Hot Isostatic Pressing www.atomising.co.uk

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Bodycote becomes first company in Sinterite renews Europe to pass MedAccred audit ISO/IEC 17025:2005

Bodycote has announced that Officer of the Performance Review Sinterite, a Gasbarre Furnace Group its facility in Derby, UK, has Institute, the organisation which Company located in St. Marys, received MedAccred accreditation. administers the MedAccred Pennsylvania, has announced the MedAccred, administered by program on behalf of the renewal of its ISO/IEC 17025:2005 Performance Review Institute, is medical device industry, sent his accreditation, allowing the furnace an industry managed approach to congratulations to the team at maker to continue to perform ensuring critical manufacturing the Bodycote Derby facility. “We certified calibrations for furnace process quality throughout the are delighted that Bodycote has users. The ISO 17025 Accreditation is medical device supply chain. the honour of becoming the first similar to the 9001 Standard, held by Bodycote Derby is the first facility company to receive an accreditation several other Gasbarre companies, in Europe to earn the MedAccred from MedAccred in Europe. To be but is more specific in requirements accreditation. the first in anything demonstrates for competence. It applies directly to Bodycote Derby offers heat a high level of foresight and organisations that produce testing treatment and Hot Isostatic commitment to a long term and calibration results and is the Pressing (HIP) services to the strategy. The MedAccred audit primary ISO Standard used by testing medical device and implants is challenging and, in achieving and calibration laboratories. markets in Europe. MedAccred accredited status, Bodycote’s Similar to the other standards, establishes stringent consensus Derby facility has proven it has ISO 17025 allows accredited audit criteria based on industry and the capability to meet and exceed companies to carry out procedures specific OEM requirements that the requirements of its medical in their own way, but an auditor ensure compliance and quality. customers. The entire team should may ask the company to justify its Joe Pinto, Executive Vice be proud of their success.” methods. President and Chief Operating www.bodycote.com www.sinterite.com

Hideshi Miura and Cesar Molins named as 2016 APMI fellows

Professor Hideshi Miura, Kyushu of the Japan Society of Powder and University, Fukuoka, Japan, and Powder Metallurgy and was co-chair Dr Cesar Molins, Director General, of the 2012 PM World Congress in AMES S.A., Barcelona, Spain, have Yokohama. been named as 2016 APMI Fellows. Miura serves on several editorial Established in 1998, the Fellow boards and has headed significant Professor Hideshi Miura (left) and Award recognises APMI members developments in ferrous press and Dr Cesar Molins (right) for their significant contributions to sinter technology, including fatigue the society and high level of expertise analysis, Metal Injection Moulding of the European Powder Metallurgy in the technology of Powder Metal- and the evolution of heterogeneous Association (EPMA) for over 20 years, lurgy, practice, or business of the PM high strength microstructures, and with two terms as President. During industry. recently developed laser based AM his presidency he was instrumental Professor Hideshi Miura is consid- for titanium and super alloys. in promoting cooperation between ered one of the leading Japanese Dr Cesar Molins has actively EPMA, MPIF, and JPMA. academics in PM. He is widely recog- promoted the PM industry for more Molins has been a member of nised by significant awards including than three decades. His deep under- APMI for over 30 years and serves the Japan Institute of Metals Distin- standing of the technology and of on the APMI International Liaison guished Achievement Award and how to best utilise the advantages Committee. He oversees several PM has contributed to over 300 publica- of PM versus other manufacturing manufacturing facilities in Spain, tions. As a member of APMI for over technologies, has contributed Eastern Europe and North America. 25 years, Miura currently serves substantially to market growth for PM www.mpif.org on the APMI International Liaison manufacturers globally. Molins has Committee. He is a past President supported PM as an active member

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HascoComposite innovations metal to advance foam can moulding stop traceability of production data which is important for quality assurance toolsbullets for injection and shield moulding from radiation purposes. The special design of the A5800 allows the unit to be flush Afsaneh Rabiei, Professor Hasco HasencleverThe Advanced GmbH Materials of Researchusing the Stratasys Objet 500 Connex mounted directly in the mould, of Mechanical and Aerospace Lüdenscheid,Lab (AMRL) Germany, at North a leading Carolina Statemulti-material production system. preferably in the risers, without any Engineering at NC State, has worked manufacturerUniversity, of moulds USA, foris reported injection to be Also announced by Hasco is the protrusions that would constitute a on developing CMFs and investigating moulding,developing recently announced a new class of metalliccompany’s new compact hot runner hindrance. their unusual properties. With a numberfoam of innovations that combines aimed the benefitssystem, the H4070, a multi-module www.hasco.com at helpingof to metal advance matrix moulding composites with design complementingsupport from the the US extension Department of total thickness of less than an inch, technologymetallic and improve foams. productivity.The composite metalof Hasco’s Energy’s established Office multi-shot of Nuclear Energy, while the indentation on the back The companyfoam (CMF) has couldjust teamed have numerous product line.Rabiei In justand fiveher teamworking showed days, that was less than 8 millimetres,” stated up with Stratasysapplications of Eden and hasPrairie, recently beenHasco promisesCMFs are to deliververy effective a complete at shielding Rabiei. “To put that in context, the Minnesota,shown USA, to to stop develop armour-piercing a rapid, system withX-rays, a fixed gamma spacing rays ofand 22 neutronmm, NIJ [National Institute of Justice] cost-efficientbullets, method as well of as producing being able to comprisingradiation. 8 or 4 modified Techni standard allows up to 44 mm low volumesshield of radiationinjection mouldedand offer extremelyShot nozzlesOther and a potential naturally applications balanced of indentation in the back of an armour.” prototypesgood by integratingthermal insulation. Stratasys manifold,CMFs fully assembled is in blast and and ballistic ready armour. The researchers have also 3D printing withThe researchits K3500 has mould focused on to install.The Nozzle results lengths of Rabiei’s of up to experiments 125 subjected the material to high system, whichdeveloping allows the a quicktechnology to processmm are availablehave shown with that nozzle CMFs tips were able speed impact testing for automotive change betweencomposite inserts metal for foams different through made fromto absorbCuCoBe the or majorTZM alloys. portion of the and train applications. These tests products.both This PM will and enable casting injection techniques. TheA furthertotal innovation kinetic energy is the of develop projectiles- showed very high energy-absorption mouldersCMF to cost-efficiently has up to eight producetimes higher ment of aeffectively, mould memory in addition unit, A5800,to stopping capabilities at a variety of impact low volumesenergy of injection absorption moulded compared to anywhich is sbothtored types permanently of type III in and the type IV speeds from quasi-static up to 100 parts for othersamples, metal prototypes foam made and from similarmould and(armour can be piercing) used to archive projectiles. all FurtherFig. 1 Examplemetres of per the second. Hasco K3500 This indicates the small productionmaterials runs. and itsHasco energy absorptionmould andstudies component-specific on the capability data. of CMFs Quick-Change to potential mould for systemutilising using CMFs in crash additivelyis manufactures almost two orders the inserts of magnitude Hasco statesprotect that against the A5800 larger offers threats full and3D printedenergy mould management inserts systems in higher under loading compared to the blast are still ongoing. trains, cars and buses. original bulk materials. “We could stop the bullet at a www.ncsu.edu

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Getrag’s joint venture transmission plant now operational in Wuhan

A joint venture between Germany’s Getrag and Chinese partner Dongfeng Motor Corp has resulted in the construction of a new transmission plant in Wuhan. The site is now operational and is expected to produce 250,000 Sunrock Ceramics specializes in high six-speed dual clutch transmission systems annually. alumina industrial ceramics for the The partners have invested €120 million (US $136.1 most severe sintering applications million) in the plant, according to a statement from of the powder metallurgy and Dongfeng, a state-owned automaker headquartered in the technical ceramics markets. central China city of Wuhan. Production capacity will reach 500,000 units by 2019 and one million units eventually. As well as supplying Dongfeng, the transmission plant will supply other automakers in China, including Dongfeng Peugeot Citroen and Shanghai General Motors, stated Xiong Aiguo, General Manager of the joint venture. Getrag is one of the world’s largest transmission makers and has a plant in Nanchang in east China’s Jiangxi province which supplies Jiangling Motor Group Co., a state-owned producer of light commercial vehicles. Getrag signed the joint venture agreement with Dongfeng in October 2012. Dongfeng makes cars and trucks under its own brand. It also has passenger car joint ventures with Honda, Nissan, Kia and PSA Peugeot Citroen. www.getrag.com | www.dfmc.com.cn

Researchers seek to extract rare earth minerals from coal

Researchers at Virginia Tech, Blacksburg, USA, are working with academic and industry partners in a $1 million pilot project to recover rare earth elements from coal and coal by-products. Funded in part by a US Department of Energy National Energy Technology Laboratory grant, Virginia Tech engineers will test hydrophobic-hydrophilic separation (HHS) technology, a patented process that takes advantage of properties of water-friendly and water-repellent materials to extract rare earth elements from coal waste. “The majority of rare earths is produced in China as by-products,” stated Roe-Hoan Yoon, Director of the Center for Advanced Separation Technologies at Virginia Tech. “With the recent closure of the rare earth mine in Cali- fornia, the US relies more heavily on imports. It will be good for the country if we can develop an advanced separation technology to extract the critical materials from coal as by-products, particularly the high-value rare earths essential for advanced manufacturing industries.” If the currently funded Phase I project is successful, researchers will seek $6 million in Phase II funding that will involve construction and testing of a mobile facility to be tested at different coal cleaning facilities in the central Appalachian coal field. www.vt.edu

GKN Sinter Metals receives Höganäs looks to improve supplier award from environmental impact of Maxon Motor transporting metal powders

GKN Sinter Metals S.p.a. AG in Bruneck, Italy, has Sweden’s Höganäs AB has announced that it is testing announced it has received a 2015 Supplier Award for “Best a new high-capacity transport (HCT) truck for carrying Overall Performance” from Maxon Motor. The award, given metal powder from the manufacturing site in Höganäs to suppliers who excel in quality and delivery reliability, to the port of Helsingborg. Working in cooperation with was presented in the “Tool-Specific Components” Volvo and GDL Transport, Höganäs claim that loading category. two containers instead of one will lower carbon dioxide Maxon Motor is the world’s leading supplier of high- emission by up to 35%. precision drive systems. The family-owned company was Each year Höganäs AB dispatches 200 000 tonnes founded in 1961 and employs a staff of more than 2,000 of metal powder from Höganäs to Helsingborg port worldwide. GKN Sinter Metals in Bruneck supplies the for further transportation to Asia and North and South Maxon Motor locations in Sachseln, Switzerland and America. The aim of the HCT project is to reduce the Sexau, Germany, mainly with bearings for electric motors number of vehicles from eight to four vehicles per day. as well as planetary gears and carriers for industrial “This is an important part of our sustainability efforts. actuators. In the future we will be able to halve the number of “We’re all very proud and honoured to receive this transports between the cities,” stated Melker Jernberg, prestigious award. It really proves that we are doing things CEO of Höganäs AB. right. We will continue this path and strive to push the The project is using the new Volvo FH16, a fuel efficient limits for highest product quality, perfect customer service truck design that also has the ability to disengage and and the most innovative products in the market,” stated raise the drive axle when unladen, further lowering fuel Marco Bernadi, GKN Account Manager for Maxon Motors. consumption. www.gknsintermetals.com www.hoganas.com

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Altus Capital Partners II, L.P. Acquires Nichols Portland from Parker Hannifin

Altus Capital Partners, an invest- Powder Metallurgy and steel compo- ment firm focused on middle market nents for fixed and variable displace- manufacturing companies in the ment pumps and the smart pump USA, has announced the acquisi- business comprises mechanical tion of Nichols Portland, a division of and electronically driven fuel and oil Parker Hannifin Corporation. Nichols pumps. Portland is a leading manufacturer Altus and the management of of precision Powder Metallurgy Nichols Portland believe that demand fixed and variable displacement for smart pump and advanced vari- gears including gerotor gears and able vane gears will increase based Nichols Portland is a leading smart pumps for automotive and upon these products ability to offer manufacturer of PM gerotors on-off highway and other industrial increased fuel and motor efficiency. markets. Altus Capital along with the “We are very excited to be partnering Russell Greenberg, Managing management team at Nichols Port- with Altus Capital Partners as we Partner of Altus Capital, added, land are reported to have made this continue to grow. Nichols Portland “Altus is enthusiastic to partner with investment in order to participate in has consistently built on its founda- Nichols Portland’s management the expected growth of smart pump tion of innovation and engineering team in acquiring an industry leader and advanced variable vane gears. excellence and we look forward to in the designing and manufacturing Nichols Portland was founded the resources that Altus Capital powder metal gerotor gears and in 1904 as WH Nichols and has its can provide to help us achieve our a growing developer of innovative manufacturing operations head- strategic growth objectives,” stated smart pumps for fuel applications.” quarters in Portland, Maine, USA. Rick Izor, Nichols Portland’s General www.gerotor.net The company’s business comprises Manager.

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GKN Sinter Metals to showcase expertise in PM and AM at Engine Expo 2016 GKN Sinter Metals has announced needs for consistency and purity. that it will showcase key Powder The company added that it is Metallurgy developments in engine able to support component design component design at this year’s by using FEA based topology Engine Expo in Stuttgart, Germany, optimisation. By using bionic May 31 to June 2. The company honeycomb or mesh structures, will also give insight into its combined with topology optimisation Additive Manufacturing capability based on differentiated material and the technology’s untapped loads, the optimal load flows within potential with a lecture at the open a minimum amount of material can technology forum during the event. be defined. Based on a series of GKN Sinter Metals states that it long-term material analyses and a offers a broad range of experience strong simulation competence, GKN for developing AM processes is enabled to optimise the structure and technologies and, as a full of the components. service provider, the company In-house materials test centres presented by Simon Höges, is offering a one-stop solution offer services for tensile testing, Manager Additive Manufacturing at for its customers. This includes service life tests, elevated tempera- GKN Sinter Metals, during the forum in-house material development of ture testing or tribological testing. on May 31 at 14:40. GKN Sinter water atomised and gas atomised The lecture, Additive Manufac- Metals will exhibit on stand 3304. powders, offering tailored powder turing – from Rapid Prototyping www.gknsintermetals.com solutions to match customers’ to Serial Manufacturing, will be

FTPL Pusher furnace half page ad artwork May 16 Print © 2016Friday, Inovar May 13,Communications 2016 3:46:32 PM Ltd Summer 2016 Powder Metallurgy Review 29 Buying and selling powder metal and furnace scrap worldwide, since 1946.

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Contact Robert Lando Email: [email protected]

co-chaired Jandeska to be recognised for lifetime both the achievements in Powder Metallurgy 1989 Powder Metallurgy William F Jandeska, Jr, President, Jandeska worked whilst completing Conference Midwest Metallurgical, Ltd., Rock- his BS, MS, and PhD from the Univer- & Exhibi- ford, Illinois, USA, has been selected sity of Illinois. After completing his tion and the to receive the Kempton H Roll PM degrees in 1971, Jandeska joined 2002 World Lifetime Achievement Award by the General Motors Research Labs for Congress Metal Powder Industries Federation a 20-year tenure, which included on Powder (MPIF). The award will be presented an appointment to assist the DoD Metallurgy and Particulate Mate- at POWDERMET2016 in Boston, National Technology Leader for GM rials, in addition to chairing the MPIF Massachusetts, June 5-7, 2016. with responsibility for high-perfor- Technical Board from 1989 to 2003. Jandeska has distinguished mance magnetics, Powder Forged Jandeska has conducted APMI Inter- himself as an expert in the field of connecting rods, main bearing caps national chapter presentations on Powder Metallurgy through devel- and development of advanced gearing technology, needs and the direction oping innovative components and materials. In 1991, he joined GM of the automotive industry; authored relationships between suppliers Global Powertrain Group as manager numerous technical papers and and vendors. He has promoted the for PM technology and lead subject presentations at MPIF/APMI annual continued growth of PM for more matter expert for the PM creativity conferences; and has held numerous than 44 years through the joint team, positions he held until his seminars educating hundreds of GM involvement of part fabricators and retirement in 2006. personnel worldwide. Jandeska is the end-user community, which is Jandeska has received numerous an APMI International Fellow, ASM evident by his support and leadership awards, including the MPIF Distin- International Fellow and received the activity in MPIF, APMI, SAE and ASM. guished Service to Powder Metal- SAE McFarland Award and the ASM Beginning his career as an intern lurgy Award and the MPIF Automo- Outstanding Young Member Award. at US Steel and Caterpillar Tractor, tive Achievement Award. He also www.mpif.org

FTPL Mesh Belt furnace half page ad artwork May 16 © 2016Friday, Inovar May 13,Communications 2016 4:13:43 PM Ltd Summer 2016 Powder Metallurgy Review 31 Call4Present_A4_ad_Layout 1 5/2/2016 1:55 PM Page 1

ABSTRACT SUBMISSION DEADLINE: SEPTEMBER 30, 2016

International Conference on Injection Molding of Metals, Ceramics and Carbides 7 FEBRUARY 27–MARCH 1 • ORLANDO Hilton Orlando Lake Buena Vista, Orlando, FL

CALL FOR PRESENTATIONS MANUFACTURING INNOVATIONS: • Part design • Tooling • Molding • Debinding • Sintering

MATERIALS ADVANCEMENTS: • Metals & alloys • Ceramics • Hardmaterials

TARGETED AUDIENCE: • Product designers • Engineers • End users • Manufacturers • Researchers • Educators • Students

CONFERENCE SPONSORS:

Metal Injection Molding Association

Metal Powder Industries Federation APMI International

Hilton Orlando Lake Buena Vista

Visit MIM2017.org or mpif.org to submit an abstract. Call4Present_A4_ad_Layout 1 5/2/2016 1:55 PM Page 1

YASA’s motors are extremely International Conference on Injection Molding Soft magnetic iron powder cores used power dense, making them the of Metals, Ceramics and Carbides in performance hybrid electric motors key-ingredient for the direct drive system.” FEBRUARY 27–MARCH 1 • ORLANDO Iron powder producer Höganäs AB high performance electric motor There are two direct drive YASA- 7 750 motors in the Regera delivering of Höganäs, Sweden, reports that its contains a number of pressed Hilton Orlando Lake Buena Vista, Orlando, FL Somaloy soft magnetic composite Somaloy 5P stator cores produced by 1600 Nm/360 kW on the rear axle powder is being used to produce the SG Technologies, Rainham, UK. for traction and a single engine stator core components for three Christian von Koenigsegg, CEO speed YASA-400 motor generator high performance electric motors of Koenigsegg stated “The three unit delivering 350 Nm/160 kW of in the hybrid drive system of the electric motors in the Regera electrical power, torque gap filling Koenigsegg Regera. constitute the most powerful electric and starter motor functionality. “The The Regera hybrid was developed motor set-up in production car torque capability of the YASA motors by Koenigsegg of Sweden as a luxury history, replacing the gears of a has given the Regera an acceleration CALL FOR Megacar alternative to Koenigsegg’s normal transmission while adding capability that is second to none,” traditional extreme, light weight, power, torque, torque vectoring added Koenigsegg. race-like road cars and is capable and yet still able to remove weight. www.hoganas.com of accelerating from 0 to 400 km/ PRESENTATIONS hr in less than 20 seconds. The car features a 5.0 litre V8 internal MANUFACTURING INNOVATIONS: combustion engine combined with • Part design three extremely compact axial flux • Tooling electric motors from YASA Motors Ltd in Oxford, UK. Together, the ICE • Molding and electric motors provide 1500 • Debinding Hp (1.1 MW) of power via a direct • Sintering drive transmission that excludes a The Koenigsegg Regera incorporates the most powerful electrical motor traditional gearbox. Each axial flux set-up in production car history MATERIALS ADVANCEMENTS: • Metals & alloys • Ceramics • Hardmaterials

TARGETED AUDIENCE: • Product designers • Engineers • End users • Manufacturers • Researchers • Educators • Students

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Brazil’s Senafor Results of event to include EFFIPRO Project PM conference to be presented

The organisers of Brazil’s 36th at World PM2016 Senafor, October 5 – 7, 2016, Porto workshop Alegre, have announced that this year’s event will include the 12th The results of the three year Members of the EFFIPRO consortium National Meeting of Powder Metal- EFFIPRO project, to develop a lurgy and 6th International Confer- significantly shorter Powder Metal- with the initial goal of producing pilot ence Powder Metallurgy – Brazil. lurgy process using a new concept plant scale equipment. Also forming part of the 36th of hybrid electrical current assisted It was planned that high perfor- Senafor will be the 20th International sintering, are to be discussed during mance metallic composites (based on Conference of Forging – Brazil; the a dedicated workshop on October 9, hardmetals, WC-Co) and engineering 19th National Conference of Metal 2016. The Energy Efficient Process metallic materials be processed Sheet Forming / 6th International of Engineering Materials (EFFIPRO) using this technology to shorten Conference of Metal Sheet Forming Project, part funded by the EU (FP7) the processing time and produce / 3rd Congress of BrDDRG as well as and industry partners, was launched materials with enhanced properties the 6th International Conference on in September 2013, with the objective (hardness, toughness and lifetime). Materials and Processes for Renew- of using the novel sintering method It was predicted that the use of this able Energy. to process hard materials with process would bring significant The conference will include improved properties, thus resulting energy consumption reduction in the lectures, keynote presentations in a more energy efficient and cost sintering process. and specially invited speakers. effective process. The EFFIPRO Workshop will take Those interested in presenting their The project intended to focus on place on Sunday October 9 during the research either orally or as a poster two different technologies, Electrical World PM2016 Congress and Exhibi- should do so before May 31, 2016. Discharge Compaction (EDC) and tion, Hamburg, Germany. www.senafor.com Electrical Resistance Sintering (ERS), www.effipro.org

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SHW Automotive: A global supplier of gear pump Technical Programme and camshaft phaser Now Available components Few industrial enterprises can look back on 650 years of uninterrupted operation such as SHW. Today, with its Powder Metallurgy plant in Aalen- Wasseralfingen, SHW Automotive GmbH is a specialist manufacturer of sintered parts for engines and transmissions and is recognised as a leading supplier of automotive pumps. Dr Georg Schlieper recently visited Hamburg, Germany SHW’s Powder Metallurgy facility and reports on the company’s activities for Powder Metallurgy Review. 9 - 13 October 2016

With a history dating back more the Ruhr Region emerged and took building in the 19th century. Rails and than 650 years, SHW AG is one of leadership in the Industrial Revo- wheels for the expanding railway the longest established companies lution. Iron ore was mined in the network and bearings for railway in the metalworking industry. Over surrounding hills and charcoal was bridges were among the key products the centuries the company has burned in the woods. When the iron of SHW at that time. re-invented itself many times and ore deposits ran dry and mining was The company’s inventive spirit was today is recognised as a techno- no longer attractive, SHW turned again demonstrated in 1925 when logical leader in the production of to casting technology and machine SHW designed an automobile that vehicle components contributing

to a reduction in CO2 emissions. At its headquarters in Aalen-Wasser- alfingen, Southern Germany, the management are proud that, thanks to the diligence, inventive spirit and a strong business acumen at SHW, the company has managed to adapt to the many changing market conditions over the years. The acronym SHW stands for Schwäbische Hüttenwerke, trans- lated as Swabian Ironworks, and the www.worldpm2016.com earliest documented evidence of the company dates back to 1365 when mining and smelting of iron ore was the main business activity. For centu- Organised and Sponsored by ries, the area in the Swabian Jura was the German centre of iron mining Fig. 1 Aerial view of SHW Automotive GmbH in Aalen-Wasseralfingen and the metalworking industry before (Courtesy SHW)

Facts and figures SHW AG has two business segments, firstly Pumps and Engine Compo- nents and secondly Brake Discs. In the Pumps and Engine Components division, SHW develops and produces engine and transmission components, including variable engine oil pumps (Fig. 2), electrical auxiliary pumps for start-stop systems and oil and vacuum pumps. Its product range also includes pumps for industrial applications. Powder Metallurgy components for use in these systems are manufactured at the SHW plant in Aalen-Wasseralfingen and the components are assembled at the plant in Bad Schussenried. In the Brake Disc business segment SHW develops monobloc ventilated cast iron brakes as well as light weight Fig. 2 The development and production of variable oil pumps is one of the main composite brake discs. The company focuses of the SHW Group (Courtesy SHW) manufactures brake disc blanks at its foundry, most of which it then was for that time highly advanced, Hüttenwerke was half owned by the finishes itself at the Neuhausen ob with an aluminium body and MAN Group, one of Europe’s leading Eck plant. independent suspension. It expressed commercial vehicle and mechanical In 2015 SHW generated group the high technical competence of engineering groups, and half owned sales of €463 million. Pumps and the company, but unfortunately by the state of Baden-Württemberg. Engine Components contributed 79% was never produced in series. The In that year both shareholders of the total business and 21% came prototype is still exhibited in the decided to end their engagement in from the Brake Disc business. SHW German Museum of Technology in SHW GmbH and the entire automo- has four production sites in Germany, Munich. tive activities were transferred into as well as facilities in Canada, China The first sintered components Schwäbische Hüttenwerke Automo- and Brazil. The group has a total staff were produced at SHW in 1962. tive GmbH, which is also the legal of around 1287 employees. From the beginning, gear pump successor and holder of the rights Currently SHW is creating a components were among the main associated with name and logo of global production network and products manufactured and this SHW. Its holding company, named expanding in to markets in North and South America as well as Asia. Facilities have been established in “...gear pump components Toronto, Canada, São Paulo, Brazil were among the main products and Kunshan, China. It is expected that these sites will soon provide manufactured and this product family a significant contribution to SHW’s sales growth. “SHW thinks and oper- grew quickly during the 1970s” ates as a global player,” stated Jörg Herrmann, Plant Manager Powder product family grew quickly during SHW AG, went public in July 2011. Metallurgy at SHW Automotive in the 1970s. In 1978 the decision was Other business units, such as Aalen. taken to assemble pump components machine tool building, machining The Pumps and Engine Compo- and manufacture the entire pump in technology, casting technology, nents business segment is divided order to increase added value. This storage and handling solutions and into three business units: Powder led to a general specialisation in forging technology became inde- Metallurgy, Passenger Cars and components of the engine periphery. pendent enterprises. All descendants Industry. The Powder Metallurgy A major turning point in the of the old SHW GmbH continue to business unit produces around 30 history of SHW came in 2005. Prior use the SHW logo with permission of million PM parts per year from a to that date, the former Schwäbische SHW Automotive. production floor space of 16,000 m².

The plant operates in three daily shifts and in 2015 a value of €57 million was generated by approximately 330 employees. Roughly half of the production is delivered inter- nally to the SHW pump assembly plant in Bad Schussenried and the other half is sold externally to OEMs and Tier 1 suppliers in the automotive industry. “Substantial investments of around €20 million have been made in the Powder Metallurgy plant during the last three years to increase production capacity to cover increasing business,” stated Herrmann. Further investments are planned with the objective of improving the production efficiency. Fig. 3 Powder press in operation (Courtesy SHW)

Technical facilities SHW Automotive GmbH has installed the entire process chain for producing powder metal parts including a tool shop, a variety of powder and sizing presses ranging from mechanical presses to hydraulic presses with 40 to 800 tons capacity (Fig. 3). The conveyor belt sintering furnaces operate at 1120°C, with synthetic gas mixtures or endogas as protec- tive atmosphere. Sinter hardening is available as well as normal cooling. A number of furnaces are integrated with powder presses in automatic manufacturing lines (Fig. 4). Fig. 4 Powder press in an automated manufacturing line (Courtesy SHW) All powder presses are equipped with balances and the weight of all green parts is automatically controlled. Feedback is given to the press and the fill height is automatically corrected as soon as the programmed limit values are exceeded. The closed-loop press control ensures maximum part-to- part consistency. Finish machining operations, for example turning and grinding operations, are an important part of the manufacturing process. The tight tolerances on the part height of most pump parts are met by double disc grinding (Fig. 5). SHW keeps height tolerances for highly efficient engine components that meet the customer requirements. Cylindrical Fig. 5 Disc grinding of top and bottom faces (Courtesy SHW)

grinding on outer diameters can test methods such as eddy current a technical and economic advan- also be offered if required. and acoustic tests are installed. tage because it avoids a separate A continuous steam treatment “Our quality management system deburring step, such as barrel furnace is installed in-house. is based on continuous improve- finishing, that might negatively However, other surface treatments ment in all processing steps. It is affect the dimensional accuracy of the products. Machining is also an important “Our quality management system is part of SHW’s technology. The based on continuous improvement in machining of green parts with cost effective drilling and milling all processing steps. It is an important operations is a well established factor in our business strategy” part of SHW’s technology portfolio. “The overall manufacturing costs of various products are lower when such as nitriding, case hardening an important factor in our business intelligent use is made of green or electroplating are supplied by strategy that contributes to the state machining,” stated Jörg external providers. reduction of manufacturing costs,” Herrmann. added Herrmann. Surface densification of Quality management sprockets and camshaft gears is Key competencies achieved in a special sizing cold SHW has a certified quality and forming process that improves the environmental management system Precision is one of the key success tooth shape and at the same time as required for suppliers of the factors following the tighter regula- increases the strength. Mechanical

automotive industry. “Statistical tory CO2 requirements. Hydraulic components such as camshaft process control procedures are parts for pumps and camshaft phaser parts achieve properties installed in every processing step phasers require extremely close close to wrought steel while still so that irregular parameters are tolerances to guarantee reduced maintaining the shape capabilities immediately detected and correc- leakage especially for the upcoming of the Powder Metallurgy process tive action can be taken,” stated fuel-efficient engine oils. In this (Fig. 6). Herrmann. A strong focus is given regard SHW has developed key SHW is one of the few to advanced preventive quality competencies in processing and PM companies worldwide management. sophisticated production equipment manufacturing sintered aluminium Besides the most common for the cost efficient mass produc- products. The benefits to the quality inspection tests, such as tion of pump and camshaft phaser customer of using high-strength dimensional and weight control, a components. and wear resistant sintered materials lab regularly monitors the One of the key competencies of aluminium components for engines material quality. Magnetic particle SHW is a special technology that include saving weight and lowering inspection is used for crack detec- combines deburring and sizing in inertia, achieving higher dynamics tion and advanced non-destructive one production step. This is both and helping to improve fuel efficiency.

A wide range of products that improve efficiency and

reduce CO2 SHW produces PM parts mainly for the automotive sector. Most applications are closely related to engines and transmissions, with roughly half of all production used in pumps. Among the remaining products, camshaft phaser parts are predominant. Individual parts for use in the car body and seat adjustment units are perhaps the only exceptions. A major focus for SHW Auto- Fig. 6 Camshaft adjustment part with densified surface (Courtesy SHW) motive is to reduce the harmful

emissions of internal combustion engines. Mechanical engine and transmission components can contribute to this ambitious task as well as innovative fuel-saving oil pump designs. SHW is determined to actively influence automotive technologies by continuous innovation of high quality PM products at competitive prices. Metal components that move relative to each other need lubrication, usually by oil. SHW’s oil pumps generate the required pressure where it is needed with a minimum of energy consumption. The company holds numerous Fig. 7 Two spur gears for an external gear pump (Courtesy SHW) patents in this field and has played a leading role in the development of pump concepts containing high External gear pumps Internal gear pumps precision PM components. External gear pumps contain two Internal gear pumps consist of a In contrast to other pump spur gears (Fig. 7), one of which is gear with internal toothing that manufacturers who purchase driven by an external power source eccentrically embraces a spur PM components from external and drives the other gear. These gear. Two examples of internal suppliers, SHW combines the gears usually include involute teeth. gear pumps are shown in Fig. 8. competence of the pump system Oil is sucked in the radial direction Various tooth shapes are used, and sintered core components of a on one side and pushed out radially for example g-rotor or duocen- pump. This tight integration results on the other side. The pump volume tric. Usually the inner rotor is the in an optimal customer benefit is determined by the gear diameter, driving gear. Oil is sucked in from regarding efficiency, packaging module and height. The quantity of oil the side in the axial direction and and, last but not least, cost. pumped can be varied by shifting the also pushed out in the axial direc- The most important product two gears against each other in the tion. family consists of gear pumps axial direction, then the pump volume Unlike external gear pumps, and variable vane pumps. Modern is reduced and oil is pumped only by a the output of internal gear pumps cars contain up to four oil pumps, part of the gear length. A variation of cannot be varied by changing the one for the engine, a primary the rotational speed of the gears also pump volume. SHW developed a and secondary oil pump for the affects the output, of course. External variable internal gear pump, which transmission and a servo pump for gear pumps are suited for medium enables the angle of eccentricity to power steering. rotational speed and high output. change in relation to the housing.

Fig. 8 Internal gear pump components produced by SHW Automotive (Courtesy SHW)

Variable vane pumps Variable oil pumps save energy because they always deliver the correct amount of lubricant according to engine demand. Variable vane pumps have an eccentric rotor with radial slots inside a cylindrical housing (Fig. 9). Vanes are mounted inside the slots that are pressed against the housing by springs, centrifugal forces or servo discs on the side faces. This creates the pump volume. Input and output of the oil is in the radial direction. Variable vane pumps provide a very uniform flow of oil. They are so designed that the rotor position can be shifted towards the centre of the Fig. 9 Variable vane pump with rotor and housing designed for PM housing. This reduces the amount of (Courtesy SHW) oil that is pumped.

Pendulum bar pump A pendulum bar pump is similar as a rotary vane pump, but it has bars which are fixed in an outer ring inside the housing and the other end is held by somewhat broader slots in the rotor. This concept has found little usage due to relatively high cost and energy consumption.

Camshaft phasers Parts for camshaft phasers are another core competence of SHW (Fig. 10). These components are mounted on the camshaft and serve to vary the ignition timing depending on the speed and load condition of Fig. 10 Camshaft phaser stator and rotor (Courtesy SHW) the engine. The engine can be run more efficiently with less emissions at partial or full loading. This serves to reduce the fuel consumption and consequently the amount of green- house gas emissions Further advantages are a higher torque and better idle stability.

Sintered aluminium parts Sintered aluminium parts offer distinct advantages as they result in lower weight components. For rotating parts, it is not only the lower weight that requires less driving energy, but more important is the lower torque of the reduced mass. In 2010, SHW Automotive received an Excellence in Powder Metallurgy Fig. 11 Cam-phaser parts from sintered aluminium (Courtesy SHW) Award from the European Powder

Fig. 12 Split gears, parts of the valve train (Courtesy SHW) Fig. 13 Helical gears for the camshaft drive (Courtesy SHW)

Metallurgy Association (EPMA) for personnel has become a high priority With its broad range of products the development of their aluminium at SHW and currently 22 young for the engine and transmission sprocket and rotor (Fig. 11). The rotor people are in apprenticeship, mainly periphery and its new strategic and sprocket are used in an automo- industrial mechanics. Two of these facilities in relevant markets world- tive camshaft phaser application and combine their industrial training with wide, SHW is well positioned to were the first known components a university education, whilst the benefit from market trends and the being manufactured from aluminium majority of the technical personnel, global demand for mobility. Process powder in large scale production. in particular press setters, are improvement, capacity expansion and Compared to a standard sintered trained in-house. Consequently, SHW an optimised international production iron cam-phaser design, weight is has a strong interest in ensuring that network are intended to help satisfy reduced from 900 g to 450 g. The engineers and technicians stay with the requirements of automotive reduced weight and lower inertias the company for a long time. customers and to boost the compa- improve the dynamic response External training is embedded ny’s competitiveness. By providing behaviour of the cam-phaser, thus in the long-term oriented employee innovative solutions for all powertrain giving another benefit to engine development training program. Short concepts the company is optimistic performance and efficiency. courses in metal powder processing for future growth. are offered by the EPMA and other Split gears organisations. SHW also takes part in The split gears shown in Fig. 12 are these courses in order to broaden the Contact used as scissor gears in a camshaft PM knowledge of its staff. Jörg Herrmann drive. The spring-preloaded gears SHW Automotive GmbH eliminate the clearance between the Outlook Stiewingstr. 111 tooth flanks, avoiding any rattling D-73433 Aalen-Wasseralfingen, noise. SHW is at the forefront of technical Germany development in engine and transmis- www.shw.de Helical gears sion pumps and a key supplier to Email: [email protected] Helical gears, a challenge for PM the global automotive industry. With technology, are also successfully tighter environmental and regula- Author produced by SHW, as shown in the tory requirements in the automo- example of Fig. 13. tive sector, the company’s focus on Dr Georg Schlieper developing products that contribute Alleestr. 101 SHW’s commitment to to a reduction in fuel consumption D-42853 Remscheid, and resulting CO emissions will Germany education and training 2 allow SHW to meet these demands. Email: [email protected] Southern Germany is a region with a Oil pumps and camshaft phasers very strong industrial structure where are becoming more complex and unemployment is low and where it is SHW is committed to growth through hard to find skilled staff. Therefore continued research and ongoing education and training of technical development of its products.

Additive Manufacturing with Powder Metallurgy June 5–7, 2016 • Boston, MA

industry experts Topics will cover: presenting the latest • materials technology • applications • technical barriers developments in this • process economics fast-growing field. • new developments

Exhibition: • trade show featuring leading AMPM suppliers

Held in conjunction with:

CONFERENCE CHAIRMEN: David K. Leigh, Stratasys Direct Manufacturing Christopher T. Schade, Hoeganaes Corporation

For program and further information contact the conference sponsor: Metal Powder Industries Federation 105 College Road East, Princeton, NJ 08540 or visit AMPM2016.org AMPM2016_AD_A4_Layout 1 2/11/2016 11:22 AM Page 1

Combining Hot Isostatic Additive Manufacturing Pressing and heat treatment: with Powder Metallurgy An elegant way to streamline June 5–7, 2016 • Boston, MA the supply chain

Combining HIP and heat treat into a single, integrated, process offers end-users an elegant way to streamline their supply chain while also decreasing shipping and handling, decreasing energy consumption and improving the delivery time for metal parts that require both HIP and heat treatment. Continued improvement in HIP equipment from the 1970s to the present day has offered the processor and the end-user increasingly advanced process options with a recent development providing a dramatic boost in what an integrated HIP and heat treat process can deliver. Dr Stephen J Mashl reports on the state of this game-changing development.

Focusing on metal Perspectives from: additive manufacturing • metal powder producers with powder metallurgy • toll providers • end users (PM), this conference • equipment manufacturers A356 aluminium, Mar-M247 nickel- When HIPing cast alloys, it is not and thus avoid incipient melting will feature worldwide • R&D from academia and consortia based superalloy, Ti-6Al-4V, Grade uncommon to pause during heating, during the final heating segment. In 91 steel, 2205 duplex stainless steel introducing an isothermal hold at this situation, it could be said that a and CPM15V Tool Steel are six metal some temperature below the final homogenisation anneal was inte- industry experts Topics will cover: alloys that are vastly different in soak temperature, in order to allow grated into the HIP cycle but more presenting the latest • materials properties and application yet all a segregated casting to homogenise advanced heat treating is possible. As technology • applications have two things in common. Firstly, • technical barriers they are often HIPed and secondly, they are typically heat treated before developments in this • process economics going into service. Hot Isostatic fast-growing field. • new developments Pressing (HIP) is a high temperature pressure treatment. For cast Exhibition: alloys such as the A356 aluminium or Mar-M247, the HIP process is • trade show featuring leading AMPM suppliers employed to eliminate the microporosity that develops from shrinkage Held in conjunction with: and decreasing gas solubility during solidification. The other alloys listed CONFERENCE CHAIRMEN: are often HIPed as powders where David K. Leigh, Stratasys Direct Manufacturing the HIP process is used to transform Christopher T. Schade, Hoeganaes Corporation the powder into a fully dense solid, Fig. 1 MIM 17-4PH turbocharger impellers are a prime candidate for either in the form of a simple billet integrated HIP and heat treat. These components operate under demanding or, using advanced HIP PM tech- high temperature, high strain conditions and thus, are commonly HIPed For program and further information contact the conference sponsor: niques, a complex net- or near-net Metal Powder Industries Federation to remove microporosity and subsequently heat treated to achieve optimal 105 College Road East, Princeton, NJ 08540 or visit AMPM2016.org shape. mechanical properties

Typical HIP thus the parts must be loaded and Alloy Published heat treat conditions temperature unloaded into process vessels twice Solution treat 540° for 12 hours and shipped from one facility to 505°C – A356 Aluminum Water quench another. Combining HIP and heat 520°C Age at 155°C for 3-5hr.1 treat is a simple, elegant, method Solution treated 955 – 970°C by which the desired structure and 900°C – Ti-6-4 Water quenched properties can be achieved while 950°C Aged at 480 – 760°C for 2-8 hr.1 providing a way for an end-user to streamline their supply chain while Solution treated 1225- 1250°C 1185°C – Mar-M247 Quench decrease processing costs and 1200°C Age 870°C.2 energy consumption. 2205 Duplex Stainless Anneal 1020 – 1100°C 1160°C Steel (UNS S31803) Rapid cool3 Combining HIP and heat Austenitize 1065-1175°C for 20–30 min. treatment CPM 15V 1120°C Quench Double Temper 540°C – 2 hrs4 The HIP process evolved from a development project in the 1950s, Austenitize 1,020-1,030°C H13 Tool Steel 1120°C Quench becoming commercialised in the Temper 250°C 5 1960s and 1970s and reaching a point in the 1980s where growing demand 1 ASM Metals Handbook, 9th edition, vol.4, American Society for Metals, Metals Park, Ohio, 1981. for HIP processing and dissatisfac- 2 G. Janowski, The Effect of Tantalum on the Structure/Properties of Two Polycrystalline Nickel- tion with long cycle times drove the base Superalloys: B1900+Hf and Mar-M247, NASA Contractor Report 17847, 1985 development of a new generation 3 Otukumpu Duplex Stainless Steel Data Sheet of HIP equipment having rapid cool 4 Crucible Industries CPM15V Data Sheet 5 Bohler-Uddeholm H13 Data Sheet capabilities. An older HIP unit might require two to three hours to reach Table 1 Comparison of HIP and heat treat conditions for selected alloys temperature and pressure set-points followed by a one to four hour soak. The final cooling and depres- shown in Table 1, the temperatures and if the parts can be cooled with surisation segment of the HIP at which many alloys are HIPed are sufficient rapidity, i.e., quenched cycle could take five to seven very close to the temperatures at within the HIP unit, then subse- hours, consuming as much time which those alloys are austenitised, quent aging or tempering can be as the other two process segments solution heat treated or annealed. performed as a follow-on process. combined. As shown in Fig. 2, the The dwell time at temperature during Conventional practice often has introduction of rapid cooling dramat- HIP is often sufficient to complete the HIP and heat treat processes ically decreased overall cycle times. the first step of a heat treat sequence performed at different facilities, While rapid cooling was introduced as way to increase productivity, engineers soon began to consider Temperature, °C Pressure Pressure, bar Temperature the rapid cool capabilities of the new HIP equipment from a standpoint of 1 - Vacuum quenching and heat treating. 1200 5 6 2 - Equalization 3 - Pumping 1000 Natural cooling 4 - Heating Cast nickel-based superalloys 800 5 - Holding Nickel-based superalloys are highly 6 - Cooling 600 corrosion resistant metal alloys that 7 - Equalization also have excellent high tempera- 8 - Backpumping 400 7 Rapid cooling 9 - Release ture properties and thus are heavily 200 3 used by the aerospace industry in 4 8 2 9 the production of disks (such as 0 1 Time, h 0 2 4 6 8 10 that shown in Fig. 3a), blades and vanes for use in gas turbines. These Fig. 2 A schematic showing the temperature –pressure profiles of a components are manufactured in conventional cool HIP cycle and a rapid cool cycle. The development of uniform cast, wrought and Powder Metal- rapid cooling capabilities in the 1980s offered the HIP operator the possibility lurgy forms. Given the life-critical of cutting floor-to-floor processing times by approximately 50%. Rapid cooling nature of many of the applications also offered the potential to quench within the HIP unit (After Bergman and and the need to maximise mechan- Skogman [3]) ical properties for operation in very

Fig. 3 A nickel-based superalloy component like the turbine disk, (a), is put through a solutionize-quench-age heat treat process in order to produce the highly desirable γ + γ’ microstructure shown on the right, (b). (Images after Orsal [6], and Linköping University [7]) aggressive environments, components made from these alloys are Probability density, Z (t) frequently HIPed. The heat treating of nickel- 0.05 based superalloys is a precipitation as HIP’ed at 1170 °C hardening process where the alloy is 0.04 /140 MPa/4h heated to an elevated temperature to form a single phase, γ, solution, 0.03 quenched, and then aged at a lower temperature to drive the formation 0.02 of the γ’ precipitates that act as a as cast barrier to dislocation movement. 0.01 The resultant dispersion of γ’ in a γ matrix, such as that shown in Fig. 3b, 0 is primarily responsible for these 0 10 20 30 40 50 60 70 80 90 100 alloys superior high temperature Time (hours) properties. Nickel-based superalloys are prime candidates for an integrated Fig. 4 The influence of HIP on the probability density function of creep lives HIP plus heat treat approach. In of Mar-M-002 turbine blades. The narrower, taller bell curve that describes 1980, in what may be the first docu- the as-HIPed specimens indicates a significant improvement in the parts’ mentation of a combined HIP and practical reliability. HIP improved both the minimum and average property heat treat process, Lamberigts, et al. values while also decreasing statistical scatter of Mar-M-002 alloy blades. present a study on the HIP of Inconel Testing performed at 760°C/695 MPa (1400°F/100 ksi). (After Lamberigts et and Mar-M nickel-based superalloys, al. [1]) noting that “If HIP is carried out at a high enough temperature, ture and properties citing advan- significant improvement in the parts HIP cycles can lead to chemistry tages of an integrated process as practical reliability. homogenisation without deleterious being reduced cost, reduced scrap In the late 1980s, ASEA Brown second phase coarsening, provided rate, better materials utilisation Boveri, Ltd. (ABB) introduced a new the cooling sequence is sufficiently and high dimensional and surface generation of HIP equipment having rapid.” These authors state that quality [1]. As shown in Fig. 4, the uniform rapid cool (URC) capabili- higher HIP pressure helps to homog- net effect of an integrated HIP and ties. As shown in the schematic in enise the gamma prime precipitate heat treat procedure was improved Fig. 5, this equipment introduced distribution, an issue that will be minimum and average property a fan, a heat exchanger and a brought up again in this paper, and values with decreased statistical cleverly designed thermal barrier note that reduced time at elevated scatter indicating that the combined that allows a controlled portion of temperature is beneficial to struc- HIP-heat treat process provided the circulating furnace atmosphere

to come into contact with the inner Cooling water wall of the water-cooled pressure connection vessel, further chilling the hot gas within the HIP unit. Bergman, West- Heat exchanger erlund, Zimmerman and Skogum published papers on this technology Thermal barrier during the early 1990s, further examining the potential to heat treat nickel-based superalloys as well as high speed steels within the HIP unit Heater using the rapid cool capability of the new generation equipment [2-5].

Powder Metallurgy duplex Gas flow device stainless steels Duplex stainless steels (DSS) are Gas flow control a class of stainless steels that have microstructures containing fractions of both austenite and ferrite, the level of austenite typically ranging from 45 to 60 volume Fig. 5 A schematic of a uniform rapid cool (URC) HIP unit. The design was percent [9]. This alloy class is known developed by ABB (now Quintus Technologies) in the 1980s in order to rapidly for possessing excellent strength cool a load of parts after the dwell segment of the HIP cycle was complete. The and toughness while also exhib- design includes a gas flow device (a fan) located in the bottom zone region of iting resistance to stress corro- the HIP unit that circulates the gas within the vessel. The forced convection, sion cracking in chloride environ- key to rapid cooling, also promotes temperature uniformity within the HIP unit. ments, and pitting. As a result of A heat exchanger resides at the top of the thermal barrier providing cooling this combination of properties, to the gas within. In addition, the flow of gas is controlled such that a portion these alloys fill a performance gap of the atmosphere circulates outside the thermal barrier, cooling as it comes between austenitic stainless steels in contact with the water-cooled pressure vessel. (After Zimmerman and and nickel-base superalloys and are Toops [8]) heavily used in off-shore oil and gas production [10-12]. Duplex stainless steel components may be manufactured by casting, forging, or using Powder Metallurgy techniques. Of those process options the HIP PM approach produces a fine grained, equiaxed microstructure, delivering isotropic mechanical properties that generally exceed those of a forging while far surpassing those of castings. The PM valve body shown in Fig. 6 is typical of the components that can be fabricated using HIP near net shape technology[13]. One obstacle in manufacturing large HIP PM components from duplex stainless steel is that the relatively slow cooling rates typical of a conventional HIP cycle result in the formation of brittle intermetal- lics on slow cooling [12]. Of these Fig. 6 A 350 kg duplex stainless steel PM valve body produced using hot detrimental precipitates, the iron isostatic pressing near net shape technology. The internal channel network is and chromium rich sigma phase formed as part of the HIP process. Valve body height is approximately 600 mm presents the greatest problem (Photo courtesy of Bodycote Powdermet AB) [10,14] while a much finer coherent

20 140 18 120 16 14 100 12 80 10 60 8 6 40 4 20

Volume % Sigma Phase Volume 2 Impact Toughness (Joules) Impact Toughness 0 0 0 5 10 15 20 25 30 1000 0 10 20 1000 Cooling Rate (°C/min) Cooling Rate (°C/min)

Fig. 7 A plot showing the concentration of sigma phase within HIPed P/M Duplok 27 samples as a function of the cooling rate within the core of the sample (left), and fracture toughness as a function of cooling rate from the 2002 study [17]. The 1000° data point is from a water-quenched specimen, other data is from either HIP-Quenched or gas-quenched specimens. While sigma phase was effectively eliminated from the samples cooled at 25°C/minute or faster. All gas-quenched and HIP-quenched specimens displayed poor fracture toughness

precipitate, α’, can form at lower Cast aluminium alloys specifications published for this temperatures causing 475°C Between 2002 and 2007, Diem, alloy require a 10 - 12 hour hold embrittlement. The conventional Mashl, Sisson and Bernard together at the solutionising temperature. solution to this problem is a post- studied the potential for combining Development work has shown that HIP solution heat treat followed the HIP and heat treat of aluminium with modern alloys and improved by a rapid quench. The potential castings into a single process processing, shorter soak times are benefit of an in situ solution heat using the A356 aluminium alloy possible in some cases. Thus as treat within the HIP is obvious and as their test material [18-21]. As detailed in a summary published by between 2000 and 2002, Mashl and indicated in Table 1, the HIP and Mashl and Diem [21] and shown in Hall conducted studies examining solution heat treat temperatures Table 2, the researchers compared that possibility [15-17]. Employing used for this alloy are sufficiently integrated HIP and solution heat a mix of conventional and rapid close to consider a combined treat processes using 4 and cool HIP units as well as in-lab process. However some heat treat 10 hour holds to conventional, gas quench capabilities, multiple samples of a superduplex stainless steel alloy were either HIP- or Description Processing gas-quenched at cooling rates Cast ranging from 1°C/min. to 32°C/ As-Cast and T6 heat treat Solution Heat Treat: 10 hours at 538°C min. The effect of gas quenching on (baseline) Water quench the concentration of sigma phase Age: 4 hours at 155°C is shown in Fig. 8 and compared Cast to water-quench data (1000°C/ HIP (Densal ®) Discrete HIP and T6 heat Solution Heat Treat: 10 hours at 538°C min.). While the faster cooling rates treat effectively eliminated sigma phase, Water quench the fracture toughness of the Age: 4 hours at 155°C HIP- and gas-quenched specimens Cast Combined HIP (Densal ®) + solution heat treat fell far short of that for the water Combined HIP + 4 hr. solution for total of 4 hours at 538°C quenched material, as shown in heat treat, quench and age Fig. 7. Subsequent fractography Water quench indicated ferrite embrittlement Age: 4 hours at 155°C thus the authors concluded that Cast while the cooling rates achieved Combined HIP + 10 hr. Combined HIP (Densal ®) + solution heat treat were adequate to avoid sigma solution heat treat, quench for total of 10 hours at 538°C and age Water quench phase formation, the rates where Age: 4 hours at 155°C not sufficiently rapid to avoid alpha prime precipitation and 475°C Table 2 Experimental conditions used in a study examining the integration of embrittlement. HIP and heat treat for aluminium alloys

discrete, HIP and heat treat and to time. Once the desired time at and fatigue properties, the cast plus heat treat, i.e., without temperature had passed (either detrimental effect of these oxides HIP. Given the need to achieve 4 or 10 hours) the castings and overwhelming any benefit that water-quench cooling rates the support tooling was unloaded hot could come from HIP. A second integrated HIP and heat treat and water quenched. round of experiments using cast cycles began as a standard HIP In a first round of experimental wedge shaped specimens, melted cycle however once the pressure work performed using and poured under conditions that segment of the soak was complete, commercial A356 aluminium would minimise oxides in the furnace power remained on during castings as test specimens, castings yielded the excellent depressurisation, maintaining the researchers found that results that follow. Average the castings at the desired soak a high concentration of thin tensile properties from the second temperature for the full allotted oxide defects dominated tensile set of trials are listed in Table 3. As can be seen, all specimens exhibited superb strength and ductility considering that many Fatigue life of A356 chilled sand casting Applied stress = 193 MPa process specifications call for R = 0.1, 50 Hz a minimum ductility level of 7% 108 elongation in this cast alloy. The lack of improvement in tensile properties with HIP was attributed 107 primarily by the fact that the simple as-cast shape contained 106 very little porosity, a tribute to good foundry practice and the Cycles to failure to Cycles simple, easily cast, shape. 105 Fatigue life is sensitive to very small amounts of residual 104 porosity as the data in Fig. 8 As-cast HIP Comb. Comb. shows. In contrast to the tensile +T6 +T6 HIP+HT HIP+HT (4h) (10h) data, the fatigue test results showed significant differences between the specimens processed Fig. 8 Average fatigue life as a function of processing route for Sr-modified using the four different methods. A356 aluminium sand castings. Typical secondary dendrite arm spacing ranged In summary, this research project from 35-45μm. Testing was performed at 193 MPa maximum stress, R=0.01, showed that an integrated HIP 50Hz with a sinusoidal waveform. Seven to nine specimens were tested under plus heat treat process was viable each set of processing conditions. The processing conditions were, from left for aluminium castings, either to right on the x-axis, conventional cast followed by conventional T6 heat treat, by quenching within the HIP unit, discrete HIP followed by conventional T6 heat treat and two integrated HIP plus provided the HIP unit could cool heat treat cycles, one with a total of 4 hours at the solutionising temperature, at a rate that was sufficient to the second with 10 hours spent at the solutionising temperature. The data satisfactorily quench the product points represent average values from seven to nine specimens processed after solutionising or by a rapid, under each set of conditions. It should be noted that two specimens from hot transfer of the product to a the combined HIP plus heat treat - 4 hour hold and four specimens from conventional furnace, followed by the combined HIP plus heat treat – 10 hour hold achieved run-out, i.e. those water quench. The improvement specimens survived 10 million cycles without failing. Error bars represent 95% in fatigue life that was observed in confidence limits specimens where a portion of the solution heat treat process had been carried out at HIP pressures 0.2% Yield Ultimate Process Elongation Reduction strength strength was not explained however, based specification % in area % MPa (ksi) MPa (ksi) on the data presented here, it T6 192.4 (27.9) 287.5 (41.7) 17.2 24.0 appears that a combined HIP and solution heat treat process could Densal, T6 187.2 (27.2) 287.5 (41.7) 17.2 23.9 offer significant property and 4-H, T6 189.5 (27.5) 289.2 (42.0) 16.4 21.3 performance improvements in 10-H, T6 196.8 (28.5) 298.2 (43.3) 17.2 20.2 addition to the benefits to supply chain and productivity. More Table 3 Average tensile properties of Sr-modified A356 sand castings research is needed.

Gas quenching at HIP pressures 1000 1830 It should be apparent from the 900 1650 three aforementioned examples of 800 1470 integrated HIP and heat treat, that 700 1290 the ability of HIP system to cool the 600 1110 material within the pressure vessel at a sufficiently rapid rate is a key 500 Vapour 930 blanket factor to success. The cooling rates 400 750 Temperature, °F Temperature, Temperature, °C Temperature, must be fast enough to avoid the 300 Boiling 570 undesired phase transformations that accompany slow cooling in heat 200 390 100 212 treatable alloys, yielding the desired Convection metastable solid solution necessary 0 32 for a subsequent aging, tempering, or 0 5 10 15 20 25 precipitation hardening treatment. Time, s

High pressure gas quenching Fig. 9 Cooling rate and cooling mechanisms as a function of time for a 25 High Pressure Gas Quenching mm (1”) diameter steel bar in still water. Upon initial quenching a continuous (HPGQ) is a technology that has insulating vapour barrier is formed and cooling is comparatively slow. Once the been seeing increased penetration vapour barrier breaks up and boiling begins cooling accelerates until boiling within the commercial heat treat stops and cooling slows as convection drives the final cooling. (After ASM market. Operating at pressures of Handbook, Vol. 4 Heat Treating) 5 – 20 bar, the advantages of HPGQ have been well characterised. As illustrated in Fig. 9, in a conventional liquid quench system, i.e., water, D A oil, etc., the interaction between the hot part and the liquid quenchant is characterised by three stages, initially a continuous insulating vapour barrier is formed and cooling is slowed, the second stage consists of nucleate boiling with very rapid heat transfer and, finally, convective C cooling after boiling ceases with a 760°C (1400°F) relatively moderate cooling rate. As 650°C (1200°F) shown in the gear drawing in Fig. 10, 540°C (1000°F) complex parts can have all three of these mechanisms active at the 425°C (800°F) same point in time thereby creating large, non-uniform thermal gradi- 315°C (600°F) ents in the parts which can lead to distortion. In contrast, quenching B in a high pressure gas environment is characterised by a constant heat transfer coefficient and, as a result, offers a higher degree of cooling uniformity and minimal distortion. Gas quenching is also inherently cleaner than an oil quenching. Given the benefits of gas Fig. 10 A drawing showing the thermal gradients within a gear section and quenching, there has been the mechanisms by which distortion occurs during liquid quenching. Trapped continuous interest in expanding vapour adjacent to the gear surface either as a vapour barrier (point B) or as gas quenching capabilities within trapped bubbles (point C) slow cooling while escaping gas bubbles (point D) industry. Driven by this, there has accelerate cooling. The net result are the asymmetric thermal gradients been a move toward higher quench within the gear (point A) (After ASM Handbook, Vol. 4 Heat Treating)

pressures. Where early high pres- The rate at which heat can transfer for any given gas increases sure gas quench equipment operates be removed from a part during with increasing pressure thus at nominal 5 bar pressures, newer quenching is controlled, in part, by increasing the gas pressures within units are capable of quenching at the ability to transport heat across the quench chamber improves the 15-20 bar pressures. This improve- the interface that is the surface of system’s ability to extract heat from ment, combined with advances the part and the surrounding quench the parts within. in heat exchangers and higher environment, i.e. water, oil, gas etc. gas velocities through the cooling This phenomenon is characterised A breakthrough in gas quenching chamber has resulted in an improved by the heat transfer coefficient at HIP pressures ability to extract heat from the parts (also called the film coefficient). While the rapid cooling capabilities being quenched. As illustrated in Fig. 11, the heat of HIP units have improved over the years, a recent advance offers a dramatic leap forward. Quintus Heat Transfer Coefficient Technologies AB (previously Avure Gas velocity = 15 m/s Conduit diameter = 0.025m Technologies AB) has recently Temperature = 500°C introduced a new system that they 2500 have named the Uniform Rapid Quench (URQ) HIP system. These 2000 systems are reported to be capable of cooling at rates exceeding 1500 1000°C/minute and further, to perform this cooling while main- 1000 taining the pressure within the HIP vessel at or near conventional 500 HIP pressures [22-25]. Thus, while current, commercial, high pressure

Heat Transfer Coefficient, W/m2K Coefficient, Transfer Heat gas quench systems can quench 0 0 10 20 30 40 50 at pressures up to 15 – 20 bar, the URQ systems are reported to Pressure, atm quench at pressures of 1000 – 2000 bar. Fig. 11 Theoretical relationship between the heat transfer coefficient and In 2015 the author, working with pressure at 500°C and 15 m/s for hydrogen, helium, nitrogen and argon. (After Quintus, set out to characterise Lin [26]) the heat treat capability of a URQ HIP system by using a URQ HIP unit to heat treat AISI 4140 steel, a 1800 common, high strength, low alloy 1600 steel that is frequently heat treated 1400 commercially [27]. With an abun- dance of data on the quench and 1200 temper response of this steel alloy, 1000 it was felt that the data generated 7.2 °C/sec 800 from HIP-quenching experiments 3.5 °C/sec using this new URQ HIP system 600 could be compared to data from 400 conventional water- and oil-quench data thus providing a semi-quanti- 200 Gas Temperature (°C) Temperature (°C), Pressure (bar) (°C), Pressure Temperature Near-Surface TC (°C) tative assessment of the URQ HIP Core TC (°C) 0 Pressure (bar) system. The experimental work employed cylindrical 4140 steel 212 214 216 218 220 222 224 226 228 specimens having a diameter of Time (minutes) 51 mm and a height of 150 mm. Select specimens were drilled Fig. 12 Temperature and pressure profiles of the cooling-depressurization longitudinally to allow the insertion portion of the URQ HIP cycle for a 51mm Ø x 150mm cylindrical steel sample. of two thermocouples, one near- The line indicating the gas temperature reflects the temperature of the HIP surface, the other on the centre atmosphere. Near-Surface TC and Core TC data represent the temperature of line, to allow the monitoring of the the sample at those locations as measured by embedded thermocouples core and near-surface tempera-

tures within the samples during quenching. The HIP cycle for the 60 integrated HIP plus 1500 bar quench cycle was as follows: 50 • Ramp from room temperature and atmospheric pressure to 1065°C (1950°F) and 1500 bar 40 (22,000 psi) • Hold at 1065°C and 1500 bar for 30 Center of bar Center

2 hours HRC Hardness, • Quench as rapidly as possible within the HIP unit while main- 20 Water Quench Oil Quench taining the gas pressure as close URQ HIP Quench to 1500 bar as possible. 10 In addition, identical specimens 0 5 10 15 20 25 30 were heated to the HIP tempera- Distance from surface (mm) ture in an air atmosphere muffle furnace, held for two hours and then Fig. 13 A plot of hardness (HRC) versus distance from the surface showing the either water or oil quenched. Disk hardness profiles for water quenched, oil quenched and URQ HIP quenched shaped specimens were cut from specimens. The drop in hardness in the near surface regions is attributed to the central region of the cylinders. decarburization. The severity of the URQ HIP quench falls in between that of Specimens quenched using each of the water and oil quench the three methods were polished, the microstructure was characterised and the hardness profile from the near-surface to the core of URQ-HIP Percent Transformed quenched, water- and oil-quenched <10 A c 1 kbar 10-30 60-90 specimens was measured and 1400 3 30-60 >90 A c 1 kbar compared. 1 A c 24 kbar A temperature-pressure profile 1200 1 from the quench portion of one URQ HIP cycle is shown in Fig. 12. As can 1000 be seen in that figure, the gas pressure remained above 1200 bar during 800 the quench, however the centre line

Temperature, °F Temperature, M 1 atm and near surface thermocouples s 600 1 atm embedded within the steel sample indicated that the bar itself cooled 24 kbar Ms 24 kbar much slower that the HIP atmos- 400 phere. Oil quenchants are published 200 to cool, on average, at rates of 0.1 1 10 102 103 104 approximately 30-45°C/sec [28]. After Time, seconds observing the data shown in Fig. 12, indicating that a URQ test specimen Fig. 14 An isothermal transformation diagram for 1040 steel at 0.1 MPa cooled at an initial rate of 7.2°C/sec, (1 atmosphere) and 2400 MPa (After Nilan [30]) then slowing to 3.5°C/sec, it was assumed that the URQ quenched steel would display a structure and iting a structure that was primarily Taken together, the data appears properties appropriate to slower- martensite with a small amount of contradictory or at least confusing. than-oil cooling. The actual results bainite. The hardness data, shown in How is it possible that the URQ HIP- were surprising. Fig. 13, corresponds to the metal- quenched specimen could cool at The microstructures of the water lographic results with the hardness a slower rate yet display hardness quenched 4140 steel specimen was profile of the URQ HIP-quenched values and microstructural features fully martensitic, the oil quenched specimen displaying hardness values associated with a higher cooling specimen was predominantly that exceeded those of the oil-quench rate? An explanation can be found bainitic, and the URQ quenched specimen while approaching that for if one examines the effect of pres- specimen was intermediate, exhib- the water quenched steel. sure on the kinetics of the γ→α+Fe3C

transformation. Research performed alloys. Researchers in Sweden and April 1994, Schaumburg, Illinois, in the 1960’s indicates that increased Germany are already presenting 1994. pressure tends to stabilise austenite, new information and technical [5] C. Bergman, J. Westerlund, F.X.

retarding the γ→α+Fe3C transforma- breakthroughs [35-37]. Zimmerman, HIP Quench Tech- tion and lowering the martensite Beyond the observed advan- nology, Proceedings of the Interna- start temperature [29-34]. The tages for ferrous alloys, Lamber- tional Conference on Hot Isostatic isothermal transformation diagram igts noted a beneficial effect of Pressing, 20-22 May, 1996. shown in Fig. 14 illustrates how, with pressure on the solution heat treat [6] C. Orsal, Nickel Applications on increased pressure, the martensite of nickel-based super alloys. The Electronics and Aerospace That start temperature is lowered and the Diem, Mashl, Bernard, Sisson Will Shape The Future, August 19, pearlite and bainite transformations effort toward combining the HIP 2015, http://born2invest.com/cdn/ are slowed. While the HIP pressures and heat treat of aluminium alloys nickel-applications-on-electronics- employed in these experiments indicated that improved fatigue and-aerospace-that-will-shape-the- do not approach that presented in performance may be attain- future/ Fig. 14, the relative influence of pres- able when solution heat treat is sure on the phase transformations performed at elevated pressure. [7] R. Bowman, Superalloys: A does explain the behaviour observed More research in this area is Primer and History, supplement in these trials. certainly needed but the future for to The Minerals, Metals & Mate- combined HIP and heat treat looks rials Society’s site dedicated to the very promising. 9th International Symposium on Summary Superalloys, http://www.tms.org/ meetings/specialty/superalloys2000/ Lamberigts, et al., noted in their 1980 Author superalloyshistory.html . paper that the use of a rapid cool HIP [8] Zimmerman and Toops , Hot system to perform a solutionise and Dr Stephen J Mashl Isostatic Pressing: Today and quench heat treatment within the Z-Met, Inc. Tomorrow, Avure Technologies, HIP unit was beneficial to dimen- Email: [email protected] http://www.hasmak.com.tr/eng/ sional control, surface quality and tozpdf/HIP-Today-and-Tomorrow. the structure and properties of cast References pdf (2008). nickel-base superalloys while also [9] Robert N. Gunn, editor, Duplex offering reduced cost, reduced scrap [1] M. Lamberigts, E. Diderrich, Stainless Steels Microstructure, rate, improved materials utilisation D. Coutsouradis, E. de Lamotte, Properties and Applications, and high dimensional control and J.M. Drapier, E. Deridder, HIP’ing Abington Publishing, Cambridge, good surface quality. These same Various Cast Engine Components England 1997. benefits appear to be available to in Nickel-base Superalloys, in producers and consumers of other “Superalloys 1980 : Proceedings of [10] Joseph R. Davis, editor, Stain- metal alloy components. Past work the Fourth International Sympo- less Steel, ASM International Hand- has shown that cast aluminium alloys sium on Superalloys”, Sept. 21-25, book Committee, Materials Park, OH, are well suited to an integrated HIP/ 1980, Seven Springs, Pennsylvania, 1994. heat treat process. HIPed Powder pp. 285-294. [11] Jaques Charles, Brayton O. Paul, Metallurgy duplex stainless steel [2] C. Bergman, S. Skogum, HIP editors, Reducing Cost by Using components would benefit from a Quenching of Aerospace Parts: Duplex Stainless Steels, Chemical combined process if sufficiently rapid Measuring of High Temperatures Processing Magazine, November cooling rates can be attained. in a Hot Isostatic Press, Proceed- 1996, Internet: www.chemical- The ability to achieve high cooling ings of HIP’93, Antwerp, Belgium, processing.com/protected/cp119 6/ rates in the core of the parts being April 21-23, 1993. techi-1.shtml (April 27 2000). processed has been an obstacle and may continue to be so, especially [3] C. Bergman, A. Träff, HIP [12] E. Hämäläinen, A. Laitinen, H. given the large size of some HIP PM Quenching, Published in “Hot Hänninen, J.Liimatainen, “Mechan- products. However, the URQ HIP Isostatic Pressing: Theory and ical Properties of Powder Metallurgy technology recently developed by Applications”, Proceedings of the Duplex Stainless Steels”, Material Quintus Technologies offers rapid Third International Conference, Science and Technology, vol.13, cooling at HIP pressures and given M. Koizumi, editor, Osaka, Japan, 1997. the beneficial effect of elevated 10-14 June, 1991. [13] Stephen J. Mashl, John C. pressure on the heat treating of [4] C. Bergman, F.X. Zimmerman, Hebeisen, Carl Gustaf Hjorth ferrous alloys, uniform rapid quench H.I.P. Quenching: A Heat Treating “Producing Large P/M Near- offers a significant advance in the Method, Proceedings of the Inter- Net Shapes Using Hot Isostatic ability to merge HIP and heat treat national Heat Treating Conference: Pressing”, JOM, Vol. 51, No 7, July into a single process for iron-based Equipment and Processes, 18-20 1999.

[14] Jan-Olof Nilsson, “The Physical ings to an Integrated HIP and Heat [29] W. Jellinghaus and H.F. Friede- Metallurgy of Duplex Stainless Treat Process, SAE Technical wold, Einfluss eines allseitigen Steels”, Stainless Steel World 97, Paper: 2004-01-1019 in Advances in Drucks auf Gefüge-umwandlungen von KCI Publishing, Zutphen, 1997, Lightweight Automotive Castings and in Stahl, Archiv für das Eisenhütten- pp. 73-82. Wrought Aluminum Alloys, SP-1838, wesen, Vol. 31, 1960, p. 309-317. [15] J.D. Hall, S.J. Mashl, The Influ- and Developments in Lightweight [30] T.G. Nilan, Morphology and ence of HIP Design and Product Aluminum Alloys for Automotive Kinetics of Austenite Decomposition Size on Sigma Phase Formation Applications: 2001-2005, PT-130, at High Pressure, Trans. Met. Soc. in a P/M Duplex Stainless Steel, in Society of Automotive Engineers, AIME, Vol.39, 1967. 2004. “Heat Treating – Proceedings of the [31] B. Lyubov, V. Tsyganenko, Theory 20th ASM-HTS Conference”, 9-12 [22] M.E. Gärdin, A Novel Heat Treat- Of The Effect Of Pressure On The October 2000, St. Louis, Missouri), ment Method with Unusual Flexibility Decomposition Process Of Austenite Edited by K. Funatani and G.E. Paper 0096, Proceedings of the 2012 In The Upper Range Of Subcritical Totten, ASM International, 2000. Powder Metallurgy World Congress Temperatures, Metal Science and [16] S.J. Mashl and J.D. Hall, The & Exhibition, 14-18 October, Japan Heat Treatment, 1968, Vol.10(2), pp. Effect of Variations in HIP Cooling Powder Metallurgy Association and 85-88. Japan Society of Powder and Powder Rate on the Microstructure and [32] E.R. Kuteliya, L.S. Pankratova Metallurgy, 2012. Properties of a P/M Duplex Stain- and E.I. Estrin, Isothermal Trans- less Steel, in “Advances in Powder [23] M. Ahlfors, The Possibilities and formation of Austenite Under High Metallurgy & Particulate Mate- Advantages with Heat Treatments Pressure, Metal Science and Heat rials-2001”, Compiled by W.B. Eisen in HIP, Proceedings of HIP ’14, The Treatment, Vol.12, 1970. and S. Kassam, Metal Powder 11th International Conference on Hot [33] S.V. Radcliffe, M. Schatz and S.A. Industries Federation, Princeton, Isostatic Pressing, 9-13 June, 2014, Kulin, The Effects of High Pressure NJ, (2001). Stockholm, Sweden, pp. 105-109. on the Isothermal Transformation [17] S.J. Mashl and J. D. Hall, [24] A. Åkerberg, The Differ- of Austenite in Iron-Carbon Alloys, Control of Sigma Phase Forma- ence between URQ™ and U2RC™, Journal of the Iron and Steel Insti- tion in a Superduplex Stainless Proceedings 11th International tute, Vol. 201, 1963, p. 143-153. Steel Through Rapid Cool HIP Conference on Hot Isostatic Pressing, [34] J.E. Hilliard and J.W. Cahn, Processing, in “HIP’02, The 2002 Stockholm, June 2014. Progress in Very High Pressure International Conference on Hot [25] A. Åkerberg, Numerical Calcu- Research, John Wiley & Sons, New Isostatic Pressing”, May 20-22, lations of URQ™ and U2RC™- York, 1961. 2002, Moscow, Russia, JSC “All- Confirming the Benefits and Possibil- [35] R. Larker and P. Rubin, Russia Institute of Light Alloys: ities of HIP-Quenching, Proceedings Uniform Rapid Quenching Enables (VILS), 2003, pp. 127-138. 11th International Conference on Hot Austempering Heat Treatment in [18] M.M. Diem, S.J. Mashl and R.D. Isostatic Pressing, Stockholm, June HIP, Proceedings 6th International Sisson Jr., A Combination HIP + 2014. Quenching and Control of Distortion Heat Treat Process, Heat Treating [26] M. Lin, Gas Quenching With Air Conference, Chicago, September Progress, Vol. 3 June/July, 2003. Products’ Rapid Gas Quenching Gas 2012, ASM. [19] M.M. Diem, S.J. Mashl, Simul- Mixture, On-line Technical Paper, Air [36] R. Larker, Austempering Heat taneous Densification and Solution Products and Chemicals, Inc. http:// Treatment During Hot Isostatic Heat Treatment of Aluminum Cast- www.airproducts.com/~/media/Files/ Pressing, European Patent No. EP ings, published in the proceedings PDF/industries/metals/metals-gas- 2294231 B1, November 20, 2013. of the 2003 ASM Materials Solution quenching-air-products-rapid-gas- Conference, 13-16 October 2003, quenching-gas-mixture.pdf . [37] A. Weddeling, N. Wulbeiter, W. Pittsburg, Pennsylvania (2003). [27] S. Mashl, A. Eklund, M. Ahlfors, Theisen, Densifying and Hardening [20] S.J. Mashl, Combining Evaluation of Ultra-High Gas of Martensitic Steel Powders in HIP Aluminum Heat Treat with Hot Pressure Quenching During HIP, Units Providing High Cooling Rates, Isostatic Pressing: A Comparison Published in “Heat Treating 2015: Powder Metallurgy, 2016. of Structure, Properties, and Proceedings of the 28th ASM Heat Processing Routes for a Cast Al-Si- Treating Society Conference” October Mg Alloy, Transactions of Materials 20-22, 2015, Detroit, Michigan, USA, and Heat Treatment, Chinese Heat ASM International, Materials Park, Treatment Society, Beijing, China. Ohio, 2015. Vol.25, No.5, 2004, pp. 546-551. [28] Houghton on Quenching, http:// [21] S.J. Mashl, M.M. Diem, The www.scribd.com/doc/42708603/ Response of Two Al-Si-Mg Cast- Houghton-on-Quenching#scribd.

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Exhibition Movie 2015

Powder Metallurgy in India: New applications for Powder Metallurgy at PM-16

The PM-16 International Conference & Exhibition on Powder Metallurgy and Particulate Materials and the 42nd Annual Technical Meeting of PMAI, organised by the Powder Metallurgy Association of India (PMAI), took place at the Hyatt Regency in Pune, India, from February 18 - 20, 2016. In his report for Powder Metallurgy Review, Professor Ramamohan Tallapragada, PM Consultant, Mumbai, India, provides an overview of the conference and highlights new applications for metal powder technology discussed at the event.

The PM-16 conference and exhibition tations, made in six plenary sessions latest in PM technology, equipment was held in Pune, India, the second and twelve parallel sessions. There and services, as well as an exhibi- largest city in Maharashtra after the were also a number of special tion of national and international PM state capital Mumbai. Pune, recog- interest sessions that showcased the companies and suppliers. nised as one of the fastest growing cities in the Asia-Pacific region, is known for its manufacturing and automobile industries as well as for its numerous colleges, universities and research institutes. The city is home to the Automotive Research Association of India and all sectors of the automotive industry are repre- sented, from motorcycles to cars and trucks. Automotive companies such as Tata Motors, Mahindra & Mahi- ndra, Mercedes Benz, Force Motors (Firodia-Group), Kinetic Motors, General Motors, Land Rover, Jaguar, Renault, Volkswagen and Fiat have established facilities near Pune. Each year, the Powder Metallurgy Association of India organises its popular conference and, each year, Fig. 1 The opening at PM-16 included the traditional lighting of the lamp the event includes a wide variety of ceremony (left to right: A Gore (Jt. Sec PMAI), Prof T R Rama Mohan (PM-16 technical presentations. This year’s Co- Chairman), N Gopinath (President PMAI) and Prof P Ramakrishnan (PM-16 conference included over 100 presen- Chairman)

Fig. 2 The President of PMAI, N Gopi- Fig. 3 C L Chu, President of TPMA, Fig. 4 Cesar Molins, Vice-President of nath, discussed opportunities and summarising the status of Powder EPMA presented an overview of the challenges for PM in India Metallurgy in Taiwan status and trends in the European PM Industry

Opening ceremony provides metallic, ceramic and cermet commercial vehicle manufacturer. overview of the PM industry powders and components. The PMAI There are approximately 28 powder, organises short courses, thematic 65 component and 52 equipment The conference began with an workshops and, of course, interna- manufacturers helping to achieve Inaugural Ceremony in which the tional conferences and trade exhibi- estimated production of ferrous and Conference Chairman, Professor tions, stated Ramakrishnan. non-ferrous components in 2015 P Ramakrishnan, welcomed dele- of about 30,500 tonnes and 10,000 gates to PM-16 and discussed the Powder Metallurgy in India tonnes respectively. The country has importance of Powder Metallurgy The President of the PMAI, N Gopi- many automotive manufacturers and as an alternative technology in the nath, in his welcoming address, gave there is an increasing emphasis on automotive, defence, aerospace, an overview of Powder Metallurgy in compact cars, stated Gopinath. energy and engineering industries India, identifying the opportunities (Fig. 1). For the past 42 years, stated and challenges to be met (Fig. 2). Powder Metallurgy in Taiwan Ramakrishnan, the Powder Metal- India is perhaps the world’s largest The plenary session continued with a lurgy Association of India (PMAI) has tractor manufacturer, second largest presentation by C L Chu, President of been promoting PM to academic two-wheeler and bus manufac- Taiwan Powder Metallurgy Associa- institutes, R&D organisations and turer, fifth largest heavy truck, tion (TPMA) that summarised the various PM Industries making sixth largest car and eighth largest status of PM in Taiwan (Fig. 3). The market for PM in 2015 was around 31,955 metric tonnes, reported Chu, with approximately 60 producers contributing towards a growth rate of around 5-7% in the region. Even though over 85% of powders are imported, the Taiwanese PM industry offers advanced technology with low production costs. For the past 25 years, the MIM process has been used to produce parts used in mobile phones and 3C products, added Chu. Around 44% of PM parts manufactured in Taiwan were used in the transport sector in 2015, stated Chu. The fact, that the auto industry in Fig. 5 Total European PM Production in 2014 by value was estimated to be Europe and USA is keen to purchase €10.2 billion (Courtesy EPMA) parts from Asia and many PM

techniques are being recognised as According to Molins, the tech- features of two rapid net shape green energy processes, is helping nology goals and trends in Europe are forming processes, namely combus- further progress of the PM industry likely to be: tion synthesis, also known as in Taiwan. • A strong co-operative push to self-propagating high temperature prove PM as a viable technology synthesis (SHS), and Laser Engi- Powder Metallurgy in Europe for main gearbox gears neered Net Shaping (LENS). Cesar Molins, Vice-President of the • Development of surface densifi- Combustion synthesis, as a European Powder Metallurgy Associ- cation as a fatigue improvement means of materials processing, ation (EPMA), gave a presentation on technology has several unique and attractive the status and trends in the European • VVT applications in growing attributes, such as self-generation PM industry (Fig. 4). He considered demand require sophisticated of energy, high reaction tempera- Europe to be in growth, although very machining, including green tures (1500 to 4000°C), short small, at around 0.4%. Total Euro- machining and very tight toler- processing times (a few seconds to pean car production is recovering, ances. a few minutes), high temperature he said, with about 15 million units • New lubricants capable of lubri- gradients and high heating and produced in 2014, and PM parts per cating at reduced addition levels cooling rates. Many intermetallic European car continued to increase to reach higher compacting compounds, particularly the alumi- to about 9.5 kg per vehicle. Euro- densities nides of nickel and titanium, can be pean PM Parts produced in 2014 • Increasing electrification of vehi- readily synthesised by the process totalled about 228,000 tonnes, with cles seems to call for new soft because of their high adiabatic ferrous structural parts contributing magnetic applications, but the temperatures and high heats of 81%, nonferrous structural parts, scope is still unclear. mixing. The combustion synthesis HIP parts and hard materials parts • Developments in bi-metal, high- of several intermetallic compounds, each around 6% and MIM compo- performance bushings the effect of processing parameters nents around 1%. Total European on the microstructures and the PM Production in 2014 by value was mechanism of synthesis in the case estimated to be €10.2 billion (Fig. 5). Memorial lectures focus of NiAl, Ti and NiTi were discussed. The powder shipments stood at about on Additive Manufacturing, Laser Engineered Net shaping is 170,000 tonnes for ferrous and at green technology and OEMs an Additive Manufacturing tech- about 25,000 tonnes for non-ferrous nology for fabrication of three- powders. MIM component sales had P R Roy Memorial Lecture dimensional metallic parts directly grown to about €275 million in 2014. Dr G K Dey, of Bhabha Atomic from computer aided design (CAD) Hard materials production slightly Research Centre (BARC), gave this solid models. Metal parts are decreased to about 14,000 tonnes in year’s P R Roy Memorial Lecture fabricated by injecting the metallic 2014. The number of Additive Manu- entitled ‘Fabrication of net shapes powder directly into the melt pool, facturing machines sold increased by combustion synthesis and by created using a high power laser by 55% to about 550 in 2014, stated using lasers’. During the presenta- beam. Each layer of the object is Molins. tion, Dr Dey discussed the prominent fabricated by moving the X-Y table

Fig. 6 Dr G K Dey, Bhabha Atomic Fig. 7 David Prakash and Paresh Turakhia of Mahindra & Mahindra, receiving Research Centre, presented the their plaque for presenting the Tamahankar Memorial Lecture from Narsi P R Roy Memorial Lecture Chandrachud

David Prakash and Paresh Turakhia of Mahindra & Mahindra Ltd. With stringent emission limits for automobiles being imposed, a major challenge for this sector is to improve the performance of automobiles whilst adopting green technologies, stated Prakash. At Mahindra, there is a continuous effort to improve fuel efficiency. Under the company’s RISE philosophy, advocating an alternative thinking approach, the fundamentals of automotive design are challenged and changed to shape the future. Among the various initiatives undertaken is the use of sintered parts. Seen as a green process, Fig. 8 V Hariharan of Tata Motors Ltd receiving his plaque from Aniket Gore for Powder Metallurgy is helping to delivering the S L N Acharyulu Memorial Lecture address the product demands, such as improved fuel economy, without reducing performance. PM offers or laser head. After completing each preplaced powder, a new layer of lightweight components and reduces layer, the head is moved up verti- material is applied on top and the wastage. Adopting such technologies, cally and the whole part is fabricated, process repeated until the part is Mahindra & Mahindra have shown layer by layer. Inert shroud gas is completed. The main goal of these their commitment to being a respon- often used to shield the melt pool layered manufacturing technolo- sible social corporate and creating a from oxidation through atmospheric gies is to produce fully dense and value offering to all stakeholders, the oxygen for improved properties of the net shaped metal parts in a single authors stated. part formed. step without special tooling involved, LENS is similar to Selective Laser in order to minimise cost and time, S L N Acharyulu Memorial Lecture Sintering (SLS) in its basic approach stated Dr Dey. The S L N Acharyulu Memorial of making solid components by a Lecture was presented by V layer additive method. Unlike selec- Tamahankar Memorial Lecture Hariharan and Deodatta Shende tive laser sintering however, the The Tamahankar Memorial Lecture, of Tata Motors Ltd., Pune, entitled metal powder is added directly while entitled ‘Alternative Thinking - ‘Unexplored Scope of Powder making the component. In SLS, a Adopting Green Technology in Auto- Metallurgy - an Auto OEM’s laser is used to selectively fuse the mobiles’, was this year delivered by Viewpoint’ (Fig. 8).

Fellow of PMAI Awards A number of Fellow of PMAI awards were presented to distinguished individuals who have contributed to the Powder Metallurgy industry. The ceremony began with a posthumous Fellow of PMAI award announced for the late Kempton H Roll. Prof Ramakrishnan spoke of Roll’s achievements and received the award on his behalf. Dayasagar Mrig, ex-GKN, received the FPMAI award for his contribution towards the development of compaction presses (Fig. 9) and Dr Vijay N Vaidya received the FPMAI award for his contribution towards production of Fig. 9 Dayasagar Mrig received the Fig. 10 Dr Vijay N Vaidya had ultrafine and nano powders and dental FPMAI award from V Srinivasan of receiving FPMAI award from V ceramics (Fig. 10). Höganäs Srinivasan of Höganäs

Fig. 11 Masanori Kikuchi, President of Porite Corp, opened Fig. 13 The PM-16 exhibition included representatives the PM-16 exhibition from national and international companies

Fig. 12 Lunch and refreshment breaks were located in the Fig. 14 Some 19 companies from India, China, Germany, main exhibition hall Sweden, Switzerland, Italy and UK exhibited at PM-16

Amongst the various automo- regarding new developments, such Codina Metallic Pvt. Ltd., Dorst Tech- tive parts manufacturing processes, as the use of PM bushes for leaf nologies, Fluidtherm, Hoeganaes Powder Metallurgy technology is in a springs / axle beams, PM coatings to Corporation, Höganäs, IMERYS unique position as it has the potential eliminate carburising, cost effective Graphite and Carbon, Innomet to produce parts with varied mate- brake pad liners to be compatible Powders, Makin Metal powders (UK) rial and property combinations, the with conventional and composite Ltd., Newmet Pvt. Ltd., Osterwalder authors stated,. brake drums / disc brakes and use AG, PMAI, Pometon India Pvt. Ltd., The PM industry, during the past of alternative process to forging for PVA Industrial Vacuum Systems few decades, has grown largely on differential gears, clutch hubs, plan- GmbH, Rio Tinto Metal Powders, the basis of the cost savings associ- etary gears to name a few. SACMI IMOLA S. C, Sharda Enter- ated with near-net shape processing prises, Singhal Sintered Pvt.Ltd., compared to other metalworking SLM Metals Pvt. Ltd., SMS Group methods. A very high degree of raw Exhibition highlights GmbH, Speciality Sintered Products, material utilisation and relatively low applications of PM in UNIMARK and Yangzhou Haili Preci- energy requirement per kg of finished the automotive and sion Machinery Manufacturing Co. part are key attractions, added Hari- engineering industries Ltd. haran. In some cases, the conversion of a cast or wrought component to The PM-16 exhibition was opened Powder Metallurgy provides cost by Masanori Kikuchi, President of Conference presentations savings of over 40%, a figure that is Porite, during a traditional ribbon demonstrate range of PM clearly moving auto OEMs towards cutting ceremony (Fig. 11). The exhi- technology the PM industry. bition included an international mix Hariharan stated that this pres- of companies based in India, China, The conference included over 100 entation was an attempt to share a Germany, Sweden, Switzerland, Italy presentations with a number of few light weighting concepts with the and United Kingdom. special interest sessions that show- audience. It endeavoured to focus on In total 19 companies were repre- cased the latest in Powder Metallurgy the expectations of the auto OEMs sented and those exhibiting included technology. The following represent

Shipments example, thereby shortening supply Total Percent of of US made AM Share chains and reducing inherent costs Shipments Category total AM made AM Products of Industry ($millions, and production time. products ($millions, Shipments 2011) 2011)* There are some parts, added Sundaram, such as helical gears, Motor vehicles 19.5% 48.0 445,289.4 0.01% two-wheeler connecting rods and Aerospace 12.1% 29.8 157,700.7 0.02% two-wheeler transmission gears, Industrial/business which are manufactured with expen- 10.8% 26.6 365,734.8 0.01% machines sive and time consuming processes. Medical/dental 15.1% 37.2 89,519.5 0.04% Perhaps consideration can be given to producing these parts by Additive Government/military 6.0% 14.8 32,784.4 0.05% Manufacturing, suggested Sundaram. Architectural 3.0% 7.4 72,186.9 0.01% Consumer products/ Additive Manufacturing of electronics, academic 33.6% 82.7 895,709.8 0.01% magnesium alloy powders institutions, and other Dr Deepak Madan of Magnesium Elektron Powders, New Jersey, TOTAL 100% 246.1 2,058,925.5 0.01% USA, discussed the laser Additive Table 1 Additive manufactured goods shipped in 2011 *These value calculations Manufacturing of magnesium alloy assume that % of each AM product is the same for US and globally. It is also powders in a paper co-authored by assumed that the share of AM systems sold is equal to share of revenue for AM Rajiv Tandon. products A spherical gas-atomised Elek- tron® MAP+43 powder with nominal a small selection of the confer- that the goods produced using Addi- size of D10=50 µm, D50=83 µm, ence presentations made at PM-16, tive Manufacturing methods in the US D90=133 µm, and nominal composi- but demonstrate the wide range of represent between 0.01 % and 0.05 tion of Mg-4%Y-3%Nd-0.5Zr was topics covered during the event. % of their relevant industry subsec- used for the Directed Energy Deposi- tors. Sundaram went on to discuss tion (DED) study. A powder with a Additive Manufacturing of the various cost factors involved in nominal particle size of D10= 8.4 automotive parts AM produced parts and the possibility µm, D50=23.5 µm, D90=42 µm of the The Plenary Session began with of applying AM technology in PM part same alloy was used for the laser a presentation entitled ‘Additive production. powder bed investigation. Manufacturing for Making Fully Additive Manufacturing has The DED study indicated grain Dense Automotive Parts’ given by become a significant technology, coarsening due to re-melting and S R Sundaram, Technical Advisor - stated Sundaram, and is no longer solidification of powder. A high Powder Metal Division, Pricol Ltd. considered just a prototyping tech- as-deposited density (>99%) could be In 2013, stated Sundaram, addi- nique. Currently, AM technologies achieved, stated Madan. Micro-hard- tive manufactured goods glob- are targeting parts for aerospace ness of the deposited layer ranged ally accounted for an estimated or medical implants, but there are from 76 to 81 HVN and residual $967 million and, of these, the US opportunities for use in the automo- porosity was eliminated via HIPing. accounted for 38% of global produc- tive sector. As well as being used for As-deposited material exhibited yield tion. To demonstrate the relative size complicated parts, AM can be used strength of 143 MPa, UTS of 195 of the AM industry, Table 1 shows to make complete assemblies, for MPa and ductility of 3.8%. HIPing

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resulted in a yield strength of 142 MPa, UTS of 213 MPa and ductility of 6.8%. The T5 heat-treatment did not change the properties of either as-deposited or HIPed samples. However, the T6 treatment improved yield, UTS and elongation. The HIPed and T6 treated samples showed a yield strength of 167 MPa, UTS of 255 MPa and ductility of 7.9%, which compares very favour- ably with as-cast WE43B (which, in a T6 condition, has a typical yield strength of 180 MPa, UTS of 250 MPa and ductility of 6%). For the Laser Powder Bed method, a combination of high 4th drive gear in M32 gearbox laser power (70-100W), slow scan speed (200-750 mm/s) and a hatch Fig. 15 Illustration of tooth root optimisation for stress reduction in a PM gear spacing between 30 and 70 µm for a six speed automotive gearbox resulted in a density of 90% of theoretical. The powder initially used in this study had a D10=8.4 Improving the machinability of PM process to consider when designing µm and had significant level of steels components. super-fines below 10-15 µm, which In the second Plenary Session at When a PM component is effected flowability, leading to PM-16, Roland T Warzel III and converted from, for instance, non-uniform spreading and higher Bo Hu of North American Höganäs machined steel by just copying the porosity. Additional trials using presented a paper on improving the existing design, the result will be a slightly coarser powder, with a machinability of PM steels. Complex sub-standard, stated the authors. By D10=23.5 µm and minimal super- Powder Metallurgy parts can require properly designing for PM from the fines, showed improved flowability machining operations to add features beginning, several advantages, for and increased the build density to not possible through compaction, to instance weight reduction and lower >98% of theoretical. meet final tolerances or to provide stresses in critical areas, can be The author claimed that the a required surface finish. Improving achieved, contributing to both better laser powder bed study showed this process can often be a chal- and more robust PM solutions. This promising results with Elektron® lenging task due to the number of also extends the application areas MAP+43 powder and further variables which can affect the final for PM to new, more demanding optimisation work is being machinability. Use of machinability components. conducted using narrower size enhancing additives is therefore an Properly designing for fatigue distribution powders of both Elek- easy and common way to improve is important in order to reach the tron® 43 and Elektron® 21 alloys. machinability of PM materials. optimal strength of a part. Fatigue The DED process can be used In the presentation, different strength is influenced by many to build simple shapes using material systems and additives different factors, such as selecting magnesium alloy powders. The were compared for machinability in the right material and process parameters and methodology laboratory and production conditions. combination, heat treatment and developed in this study can be used Large improvements in tool life were so on. However, in many cases, the as a platform to develop protocols observed for the advanced mate- strength of a component can also for scaling up. A high laser power rials and additives which improved be greatly improved by smart design (1750-2250 W) was necessary productivity. modifications, such as reducing to achieve good quality deposits or removing stress concentra- with densities exceeding 99%. The Fatigue considerations for Powder tions. Often small modifications can resulting mechanical properties of Metallurgy components be introduced that will decrease the as-deposited Elektron® MAP+43 Thomas Schmidtseifer, Michael stresses. Fig. 15 shows an example showed yield strength of 170 MPa, Andersson and Anders Flodin of of a tooth root optimisation for stress UTS of 250 MPa and elongation of Höganäs AB, Sweden, presented reduction in a gear for a six speed 6.5%, which compares very favour- a paper, ‘Design for fatigue with automotive gearbox, where the PM ably with as-cast WE43B (in a T-6 PM’, that highlighted important solution showed 18% lower stresses condition), stated Madan. aspects of the Powder Metallurgy compared to the machined solution.

The paper demonstrated how pre-alloyed elements in the base of higher performance sinter- design modifications can be iron affects the transformation hardenable grades, Ancorsteel 4300 introduced to make a more robust products found after sintering. The provided good dimensional preci- fatigue design when converting cooling rate, pre-alloyed elements sion. components to PM manufacturing. and admixed additions determine Examples were given for applica- the final microstructure, dimen- Characterisation of iron powder tions such as gears and connecting sional change and mechanical mixes rods. For instance, consideration properties in the sintered compact. Prakash Khole, Chantal Labrecque, was given to how the tooth root of a Four premixes were prepared Maryam Moravej and Ian Bailon- gear can be redesigned, or the stem as shown in Table 2. The mixes Poujol, of Rio Tinto Metal Powders, of a connecting rod, to reduce the containing atomised Acrawax C discussed the characterisation of stresses in the component. were conventional premixes iron powder mixes prepared with a The importance of suitable prepared via double cone blending. compressible iron powder. fatigue data was exemplified by The premixes containing the warm Atomet 31 is a compressible iron showing how full SN-curves can be die lubricant (AncorMax 200™) powder that is produced via iron used to determine the service life of were prepared via a proprietary granulation, grinding and decarburi- a part under load spectra and what premixing process. These premixes sation. This product was specifically design modifications translate into were utilised to evaluate the developed for the Indian market and in terms of fatigue life. It was also dimensional change variability is suitable for applications requiring shown how suitable fatigue models during the heat-treat response of a good compressibility and high green can be applied to stress concentra- prototype gear. The gear geometry strength, such as bearing parts, tions to make sure that the material used is shown in Fig 16. Approxi- pulleys, oil pump parts and valve is optimally used. mately 1,000 gears were made from guides. each premix, The paper gave details of this Dimensional control in Powder The authors reviewed the benefit product from its production step to Metallurgy components of using a 0.3 prealloyed Mo grade the final properties obtained in Fe-C Powder Metallurgy is a net shape powder with FC-0208 type of and Fe-Cu-C mixes as per MPIF process and hence an under- powder both in as sintered and heat Standards F-0005, F-0008, FC-0205 standing of what controls dimen- treated condition. For heat treated and FC-0208. The effects of different sional change is important. In the parts the use 0.3%Mo without Cu types of additives (Cu, graphite) on presentation by Fran Hanejko, Bruce was found to give a better dimen- the sintered properties were evalu- Lindsley of Hoeganaes Corporation, sional precision than FC-0208. ated. Finally, an FC-0208 formulation USA, Kalathur S Narasimhan of P2P FC-0208 parts, made with with 0.45% Fe3P was included in the Technologies, USA, and Mahesh the Ancorbonded binder/lubri- study in order to assess the addi- Kamble of Speciality Sintered, cant approach used in making tion’s specific effect on the mechan- India, factors affecting dimensional higher density AncorMax 225 ical properties. Microstructures and control in PM parts were discussed. powder, provides a tighter dimen- apparent hardness obtained under Alloying elements such as C, sional tolerance by ensuring all various conditions were compared to Mo, Ni, Mn, Cr and Cu increase the the graphite goes in to alloying those achieved with a reference steel hardenability of steel, stated the compared with a non- bonded powder. authors. Further, the amount of mix. It was found, that in the case

Mix Base Iron % Copper % Graphite % Lube & Type

Unalloyed iron 1 2 0.8 0.75% Acrawax powder Unalloyed iron 0.4% warm die 2 2 0.8 powder lubricant Prealloyed 0.3% 3 Molybdenum 0.75% NA 0.8 Acrawax Prealloyed 0.3% 0.4% warm die 4 0.8 Molybdenum lubricant

Table 2 Composition of premixes Fig. 16 Spur gear produced to evaluate part-to-part consistency in the heat-treated condition

Award winning (a) (b) (c) components A flyweight assembly manufactured by Pricol, received the Best PM Part award from the PMAI. The complex component is part of a diesel fuel injection pump and consists of a flyweight carrier, cylindrical gear and bi-metal Fig. 17 The flyweight assembly involves joining the two parts, (a) and (b), by bush. Made from three different projection welding. The joined component is shown in (c) materials, the part involves joining two parts of dissimilar chemistry A Certificate of Excellence was A further Certificate of Excellence by projection welding (Fig. 17). The presented to GKN Sinter Metals was presented to Speciality Sintered parts are heat treated to achieve for a hub component used in an Products Pvt Ltd for an annulus the required properties specified automotive transmission clutch assembly for use in starter motors. by the customer. assembly.

The influence of copper powder achieved by the single press and These properties can be improved features single sintering process, thus by carburisation heat treatment. The influence of copper powder avoiding large shrinkage during However, in their existing design, features on the performance of sintering in order to keep close toler- such processes can lead to increased copper-based sintered components ances. costs. was discussed by I. Rampin, F Paul Skoglund of Höganäs AB, Mahindra & Mahindra Ltd has Bortolotti, M Zanon and A Breda of Sweden, gave a presentation entitled developed quill gears through a Pometon Powder S.p.A., Italy. ‘High density compaction solutions, Powder Metallurgy process. The Copper and copper alloy powders efficient lubricants’. Recent develop- technique involves rapid cooling in are used in several industrial applica- ments with more efficient lubricants the furnace to generate high strength tions, the prominent one being in and powder mixing concepts open and wear properties, using optimised electric and electronic industries up new possibilities to produce PM material composition and sintering due to their excellent electrical components to high density in a cost conditions. Success is achieved in the and thermal conductivities, stated efficient way. The possibilities of development of quill gears via sinter Rampin. The most common copper combining high performance lubri- hardening, avoiding the use of forging powder production processes, such cants with best practice compaction and a second hardening process. as atomisation and electrolysis, procedures were discussed. This presentation discussed material obtain the required shape and size composition, the sinter hardening distribution through control of Powder Metallurgy transmission process, a comparison of mechanical process parameters. These charac- quill gears and metallurgical properties and teristics affect the performance of Transmission quill gears are tradi- validation of the results. copper based sintered components. tionally hot forged steel parts, often The influence of different copper used in constant mesh manual trans- Properties of MIM 440C made by powder types and process properties missions. G Magendran of Mahindra pre-alloy and master alloy routes such as compaction pressure, dimen- & Mahindra Ltd., Pune, presented Martin A Kearns, Mary-Kate John- sional change, final sinter density the latest developments in manufac- ston, Keith Murray and Paul A Davies and electrical conductivity were turing these interesting components of Sandvik Osprey Ltd., UK, Viache- discussed and guidelines for optimal via the Powder Metallurgy route. slav Ryabinin and Erainy Gonzalez powder selection recommended. The quill gear allows a drive shaft of TCK S.A., Dominican Republic to shift its position relative to its presented a paper entitled ‘Studies High density solutions and efficient driving shaft either axially, radially or on the Effects of Nb on Sintering and lubricants both. It has external teeth which are Properties of MIM 440C made by Pre- There are a number of possible positively engaged with the interme- alloy and Master Alloy Routes’. routes for achieving higher density diate gear and sleeve, which permits According to Paul Davies, one in PM components, such as high the required motion to the drive shaft. of the most versatile alloys in use temperature sintering, copper Quill gears directly engage with shift in Metal Injection Moulding is 440C infiltration, liquid phase sintering gears on the outer surface and bear- martensitic stainless steel, which and double pressing. It is, however, ings on the inner surface. They need offers high hardness and good corro- attractive if high density can be to have high strength and durability. sion resistance. This combination is

Lot # 121014-1 (440C) 121114-1 (440C(Nb)) 121214-1 (440C(Nb) MA)

Density % 99.4 99.2 93.3

Final %C 1.06 1.21 1.09

Hv10 hardness 310 413 244

Surface 500x

Micron bar = 500µm

Centre 500x

Micron bar = 500µm

Fig. 18 Microstructures of different alloy variants after sintering at 1260°C

suited to service in automotive fuel be at the cost of enlarged grain size Soft magnetic composites for injector parts, medical pliers and a and lower final hardness levels. automotive applications range of tool parts, for example in Niobium is helpful in restricting K Malobika, B Aviral, H Y Neha, C textile machinery. Achieving repro- grain growth and maintaining hard- Dibyendu, Ch Raju Satyanarayana, ducible properties and consistent ness levels. Carbon loss during the V Chandrasekaran and R Gopalan hardness requires close control of sintering process is predictable of International Advanced Research carbon levels, in particular. for gas atomised powders with Centre for Powder Metallurgy and There are a number of variants and without blended carbonyl iron New Materials (ARCI) and Research on 440C in use today, some with powder and is dependent only on Centre Imarat (RCI) in Hyderabad, enhanced carbon levels to achieve the amount of oxygen present in the presented a paper discussing the higher hardness and some with starting powder and not apparently promises and challenges of soft additions of Nb which are claimed on the sintering temperature in magnetic composites for automotive to increase the sintering process the normal sintering range 1240- applications. window for the alloy. The study 1280°C. Soft magnetic materials (SMM) for showed that sintering 440C in In common with previous studies automotive applications demand high nitrogen at 1240-1260°C is effective on other master alloy systems magnetic induction, high perme- in achieving virtually full part density it was stated that part distortion ability and low core losses at the for 80%-22 µm PA powders with and appears more pronounced in parts operating frequencies. These can be without Nb present (Fig. 18) and that made with pre-alloyed powders achieved by selecting or designing the sintering temperature required compared with master alloy materials with high magnetisation for full density is dependent on the powders. This may be one reason ‘Bs’, low coercivity ‘Hc’ and increased balance of C and Nb in the alloy. to adopt a MA route albeit a higher electrical resistivity ‘ρ’ to effectively Higher temperatures are needed to sintering temperature will be reduce the eddy current losses. obtain full density in parts made via needed to achieve full density. Fe-based soft magnetic mate- a master alloy route: A 90%-22 µm The author concluded that rials are useful for low to moderate grade enables full densification at gas atomised 440C pre-allloy frequency applications with phos- 1280°C while the 80%-22 µm grade and master alloy powders are phorus, aluminium and silicon as reaches 97% density at this tempera- both ideally suited to producing the usual alloying elements. For ture. The densification behaviour high performance components high frequency applications (>1 kHz), can be rationalised with reference to to close tolerances with excellent ferrites are the most popular Thermocalc studies. control of carbon leading to materials. However, ferrites have While achieving peak density is uniform shrinkage and predictable drawbacks of having relatively low desirable, it was stated that this may properties. values of magnetic induction ‘Bs’ and

permeability ‘µ’as compared to those and sintered densities in excess of technology is currently being utilised

in Fe-based soft magnetic alloys, the 7.4 g/ cm³ at compaction pressures of in the production of high density authors stated. approximately 750 MPa. automotive and non-automotive Soft magnetic composites (SMCs) While the PM process produces ferrous components, providing parts are typically iron or iron based alloys net or near-net shape components, producers another tool to improve the having an insulation film of either many parts are machined to deliver manufacturing and cost competitive- organic or inorganic coating on the high precision features, cross ness of PM components. surface developed through either holes, transverse grooves, etc, the milling or solution techniques for author stated. It is estimated that Innovative Hot Isostatic Pressing automotive applications, wherein the 40-50% of PM steels require addi- methods operating frequencies are > 1kHz. tional machining in applications Dr G Appa Rao of Defence Metallur- PM processing provides flexibility where wrought steels are normally gical Research Laboratory (DMRL), in either alloying or additions of employed. Components with poor Hyderabad, discussed innovative non-magnetic materials to the base machinability result in higher insert Hot Isostatic Pressing methods and systems so as to alter the electrical costs, reduced capital utilisation and identified the development of critical and magnetic properties. PM based unpredicted downtime. components using this process. SMCs are amenable for the mini- One of the advantages of PM is Hot Isostatic Pressing (HIP) involves mising of the magnetic anisotropy that machinability enhancers can be simultaneous application of inert normally present in conventional incorporated into the powder prior gas pressures up to 200 MPa and laminated sheet metal technology of to compaction. Engineered powders high temperatures up to 2000°C. silicon steels. with enhanced attributes are an HIP processed materials and objects The unique properties of SMC important tool for developing new exhibit near 100% theoretical density include isotropic behaviour for parts and improving current applica- and isotropic properties with large three-dimensional flux distribution, tions. A newly introduced machining sizes and near net shapes. relatively low core loss at medium enhancer, AncorCut, was found to Applications such as consolida- and high frequencies, improved improve machinability of a variety of tion of a wide variety of particulate thermal characteristics, flexible alloy systems and microstructures, materials into near net shaped machine design and 3D design solu- stated Chandrachud. This benefit components, diffusion-bonding of tions. The evolution and evaluation of in machinability was observed with similar/dissimilar materials and these SMC systems, with emphasis both turning and drilling of several defect-healing of investment cast on automotive applications, were different alloy systems (Fig. 19). components were discussed. The presented in this talk. The new additive also avoids the chemical composition, purity levels, At ARCI, an R&D programme accelerated corrosion (rusting) found physical characteristics and phase has been initiated with the aim of in sintered PM parts containing MnS structure of powders as well as the obtaining an electrically insulating and provides stable machining char- encapsulation materials, together layer on the iron powder and further acteristics. Chandrachud discussed with HIPing cycle parameters, greatly hot consolidation using conventional how this new advanced premixing influence the performance of the as well as spark plasma sintering. Typically, magnetic induction ‘Bs’ of 1.5-1.6 T, coercivity values of ‘Hc’<2 Oe with permeability ‘µ’ >4000 1000 were achieved in samples with rela- 900 tive densities of ~ 96%. The studies 800 on SMCs, with their microstructural 700 features and magnetic property measurements, were highlighted. 600 500 Enhanced processing developments 400 in steel powders Number of Holes 300 Bruce Lindsley, Fran Hanejko and 200 Cecilia Borgonovo of Hoeganaes Corporation, USA, submitted a paper 100 focused on enhanced processing 0 developments in steel powders. No Additive MnS AncorCut The paper was presented by Narsi Chandrachud and discussed how warm die compaction with AncorMax Fig. 19 Carbide drill life in FD-0405 with no additive, MnS and AncorCut at 225 binder/lubricant enables green 3500 rpm and 508 mm/min feed

HIPed products to meet the specific Thus, the basic requirement of any “Free” sintering or pressure- requirements, stated Dr Rao. The consolidation technique is to limit less sintering of diamond tools in strategies and innovative approaches the maximum processing tempera- a batch or continuous furnace with adopted in the development of HIPed tures to much less than 1000ºC, controlled reducing atmosphere is a products for various applications so that the cutting properties of viable option, stated Krishnamurthy, were discussed. diamonds are not greatly affected. though fraught with operational and To date, Direct Hot Pressing is technological challenges. Most of the Particulate materials in diesel the most preferred consolidation diamond tool manufacturing level pollution control technique for the manufacturing of is small due to the high cost of raw Powder Metallurgy and particulate metal-matrix diamond tools. The materials, complicated processes, materials, by being a green tech- processing temperatures and pres- expensive machinery, large number nology, offers a variety of solutions sures are in the range of 750-950ºC of required formulations and types of to combat pollution effects by way of and 25-50 MPa, respectively, in tools and business cycles. offering unique electrodes, materials high density, high conductivity The switch over to pressure-less for incinerators, nano and activated graphite moulds with rapid heating sintering also throws up challenges in the choice of materials for the matrices. There is a need for cost “There is a need for cost effective, ultrafine effective, ultrafine powders sinter- powders sinterable at less than 950ºC, with able at less than 950ºC, with good pore free density and tailorable wear good pore free density and tailorable wear resistance and toughness, joinable by resistance and toughness” diffusion bonding/ brazing/ welding, and secondary operations as the need demands. Some of these aspects were catalysts, porous membranes, filters, cycles. The classical matrix has discussed. foams and honeycombs as catalyst been cobalt, especially made from supports. ultrafine powders. New lubrication systems for Dr T R Rama Mohan, Consultant To modify the matrix-diamond improved performance in Powder Metallurgy, Ceramics and interface, mechanical properties, Shock absorber parts such as Diamonds, presented a paper on wear characteristics and to reduce pistons, cylinder ends and rod guides the use of particulate materials in cost, various additives are included are multi-level parts with rather diesel pollution control. This paper such as iron, nickel, copper, tung- complex geometry. These are often focused on metallic and ceramic sten, sintered cobalt-cemented produced by means of PM due to the honey combs as catalyst supports tungsten carbide (WC-Co), plain net shape and design freedom the and particulate filters used in auto- tungsten carbide (WC), fused tung- process offers, in combination with

mobiles, in particular diesel-engined sten carbide (W2C), Misch metal the dimensional precision that is a

vehicles. powders, yittrium Oxide (Y2O3) etc. critical requirement. Mahesh Nipan- Hot pressing times are in the range ikar of Höganäs India Pvt. Ltd, Pune, Novel sintering of diamond tool of three minutes at temperature. discussed new lubrication systems matrices Matrices are formulated based on that offer improved performance in Diamond Tools are particulate cobalt-, iron-, nickel- and copper- powder mixes suited to the production composites, in which, predominantly, based compositions. of these parts. synthetic single crystal diamonds Hot pressing is the rate limiting The relatively low density, in are dispersed or impregnated in a process in the production of combination with the complex geom- metallic or ceramic/ inorganic or diamond tools. The capital cost of etries and the demand for dimen- thermoset polymer matrix. Each hot presses and power require- sional accuracy, make the sponge protruded point of the single crystal ments due to multiple installations iron powders a natural choice for diamonds present in the composite and to cope with production require- the shock absorber parts. The new acts as a single point tool. Dr Murli ments make it a very complicated lubricant and mix system, developed Gopal Krishnamurthy, Consultant, operation. Moreover, the use of by Höganäs, further improves dimen- Novoken Innovations, Mumbai, expensive graphite moulds is prone sional stability and, in particular, presented a paper discussing the to oxidation, wear, breakages and green strength. This system, Intralube ‘free’ sintering of diamond tool the like. They also add greatly to the S, is tailored to work with sponge matrices. cost of production. Expanding appli- powders at low densities. It is a Deterioration of diamond occurs cations and the need for smaller Zn-free and environmentally friendly due to heating to high temperatures. tool bits make it uneconomical for system. The optimal operating condi- In the presence of metallic elements, hot pressing to be sustained as a tions and achievable properties of the catalytic graphitisation occurs. major manufacturing process. lubricant system were discussed.

Awards recognise significant work in Powder Metallurgy research and development This year’s event included a number of awards for students and researchers aimed at rewarding outstanding research work presented at PM-16. An expert committee evaluated the submissions and the awards were Fig. 20 SEM images of Ti12Mo6Zr2Fe powder by mechanical alloying method presented during the conference. for 45 min (a) general aspect of the powder, secondary image (b) detail of the powder, back-scattered image Grand Student Award The winner of the Grand Student microstructures of these powder of Technology, Bombay (IITB), Award was announced as Prakash mixing processes was compared. Kambale identified the effect of Mohan, PhD Scholar at the Univer- The addition of small amounts nano sized starting materials on the sity Polytechnic of Valencia, Spain. of Fe further increased β-phase dielectric and ferroelectric behaviour In this award winning paper, stability, improving the properties of barium titanate. co-authored by Angelica Amigo of Ti–15Mo–6Zr–xFe alloy, stated Barium titanate is a ceramic Mata and Vicente Amigo Borrais, Mohan. widely used in the electronic industry Institute of Materials Technology due to its high dielectric constant (ITM-UPV) University Polytechnic of Guiding Hand Faculty Award and low tangent losses. Barium Valencia, Spain, Mohan discussed This award is presented to the titanate used in electronic circuits the effects of Fe and Mo content on principal lecturer of the winner is not in powder form but as a the microstructure and mechanical of the Grand Student Award. As sintered product with shape formed properties of Ti-Mo based alloys Mohan’s lecturer, Dr Vicente Amigo as per the component design. Thus, prepared by elemental blend and Borras, University Polytechnic of it becomes important to study mechanical alloying techniques. Valencia, Spain, received the prize. sintering characteristics of barium Titanium and its alloys are titanate. The main objective of the commonly used biomaterials due Young Professional Award research work was to synthesize to unique properties such as high A Young Professional Award was barium titanate from micron sized corrosion resistance, low elastic presented to Dr Kaustubh Kambale, barium carbonate and titanium modulus, high mechanical strength Assistant Professor, Department oxide having different particle size to density ratio and good biocom- of Metallurgy and Materials (0.7 μm, 50-60 nm and 80-90 nm) patibility, stated Mohan. Ti β alloys Science, College of Engineering, and study the effect of particle size based on the Ti-Mo alloy system Pune. In the paper co-authored of starting materials on sintering offer much interest to biomaterials by Ajit Kulkarni and Narayanan characteristics and dielectric and researchers. The addition of Zr and Venkataramani, Department of ferroelectric properties of barium small amounts of Fe improves the Metallurgical Engineering and titanate. β-phase stability, improving the Materials Science, Indian Institute properties of Ti-Mo alloy. These alloys can be produced by Powder Metallurgy using Elemental Blend (EB) techniques (600 MPa compaction pressure) and Mechanical Alloying (MA) techniques at 600 and 900 MPa compaction pressure (Fig. 20). The paper described the microstructural characterisation obtained by SEM and physical and mechanical properties obtained by bending tests, Archimedes tests and ultrasonic tests of Ti-Mo- Fig. 21 Back scattered electron micrograph of tungsten heavy alloy after Zr-Fe alloys made by EB and three cycles of heat treatment showing penetration of the matrix phase MA. Mechanical properties and (shown by arrow)

Dhokey, S Dhokale and P Ghosh. In the research work, forging was carried out as a secondary densification process on Astaloy (0.85% Mo+0.3% C) atomised powder (Fig. 22). Cold compaction of the powder was done at 600 MPa followed by sintering at 1120°C for 30 min. Three forging temperatures (800°C, 900°C and 1000°C) and three strain rates(0.1s-1, 0.2s-1, 0.3s-1) were selected for forging parameters optimisation. Two surface treatments, namely carburising and carbonitriding, were carried out on the optimised forged samples. Powder shape and size was characterised using SEM and sieve analysis. Cold compacted and sintered specimens were characterised for Fig. 22 SEM image of Astaloy 0.85% Mo+0.3%C+1 % Zn stearate powder hardness, wear, density, tensile and transverse rupture strength. Micro- structural characterisations of the Young Professional Award by liquid phase sintering followed differently treated specimens were A further Young Professional Award by heat treatments which consisted carried out using optical microscope. was presented to U Ravi Kiran, single as well as multiple cycles The results indicated that forging Defence Metallurgical Research (Fig. 21). Subsequently, these were at 1000°C and 0.3s-1 strain rate gave Laboratory, Hyderabad. The paper, subjected to warm swaging imparting approximately 98% density and 90 co-authored by Sankara Narayana about 20% deformation. HRB. Carbonitriding gave improved and T K Nandy, Defence Metallur- Discernible changes were hardness and wear resistance than gical Research Laboratory and G V S observed in the microstructure carburised steel. Nageswara Rao, National Institute of following cyclic heat treatment in Technology, Warangal, focused on the both heat treatment and swaged effect of cyclic heat treatment and conditions. Cyclic heat treatment Author swaging on mechanical properties of results in separation of tungsten cobalt and molybdenum containing grains, thereby decrease in conti- Prof Ramamohan Tallapragada tungsten heavy alloys. guity both in cobalt and molybdenum PM Consultant, Tungsten heavy alloys (WHA), containing tungsten heavy alloys. Mumbai, prepared by liquid-phase sintering, While there was marginal improve- India. are composite materials in which ment in tensile properties, impact Email: [email protected] quasi-spherical shaped hard bcc toughness showed significant particles are embedded in the enhancement. PMAI ductile Ni–Fe–W solid solution fcc A detailed analysis of micro- matrix. Tungsten heavy alloys offer structure and fractographs was Powder Metallurgy Association of a unique combination of properties undertaken in order to understand India such as high density (16–18 g/cm3), the reasons for the enhancement in B 1002 Kingston, High Street, high strength (1000–1700 MPa), high impact toughness and also the impli- Hiranandani Complex, Powai, ductility (10–30%), good corrosion cation of these results in the develop- Mumbai, 400076, resistance, and easy machinability. ment of heavy alloys with enhanced India One of the strategic applications for properties. Tel +91 22 25704588 these alloys is in ordnance, such as Email: [email protected] kinetic-energy penetrators. G S Tendolkar Award www.pmai.in In the study, a tungsten heavy alloy Vijai Thavale, Assistant Professor, containing cobalt and molybdenum Department of Metallurgy and Mate- was subjected to thermo-mechanical rials Science, College of Engineering processing that employed cyclic heat Pune, received the G S Tendolkar treatments in order to explore the Award for the paper Forgeability of possibility of enhancing mechanical Astaloy and its Response to Thermal properties. The alloy was synthesized Processing, co-authored by N B

Additive manufacturing is completely changing the production process. Moving beyond 3D printing’s benefits for design and prototyping, it is today a technology that also allows for the creation of complex new products with entirely new properties – lighter, stronger and less wasteful. Come to Additive Manufacturing Europe 2016 at RAI Amsterdam and see the latest technology in action, from full AM/3D printing systems, software solutions, scanning and imaging equipment, finishing solutions and material innovations. It’s the entire advanced design and manufacturing ecosystem in one place! Discover how even small changes can have a big impact on your manufacturing lead times and processes and hear practical case studies from the aerospace, automotive and healthcare sectors. 2 HALLS | 3 DAYS | UNLIMITED OPPORTUNITIES!

PM Industry Advertisers’ Events Index 2016 ACE Iron & Metal Co. 30 Additive Manufacturing Europe 2016 71 AMPM2016 Additive Manufacturing with Powder Metallurgy American Isostatic Presses, Inc. 12 June 5–7, Boston, USA ALD Vacuum Technologies 22 ampm2016.org Ametek 6 POWDERMET2016 International Conference on AMPM2016 44 Powder Metallurgy & Particulate Materials Cremer Thermoprozessanlagen GmbH 21 June 5–8, Boston, USA Da Chen Molding Co., Ltd. 7 powdermet2016.org Dorst Inside back cover ICMME 2016: 18th International Conference on Elnik Systems 9 Metal Materials and Engineering June 27-28, Copenhagen, Denmark EPSI - Engineered Pressure Systems Int. N.V. 10 www.waset.org Erowa 11

Additive Manufacturing Europe 2016 Fluidtherm 29/31 June 28-30, Amsterdam, The Netherlands Formnext powered by TCT 56 www.amshow-europe.com GEA 14 EPMA Powder Metallurgy Summer School 2016 Graphit Kropfmuehl GmbH 16 June 27 – July 1, Valencia, Spain HC Starck 33 www.epma.com Hoeganaes Corporation Inside front cover Symposium and Exhibition on Additive Höganäs AB Outside back cover Manufacturing (SEAM 2016) Imerys 18 July 26-27, Seberang Jaya - Penang, Malaysia www.seam2016.com Keystone Powdered Metal Company 8 Lonza Inc. 17 ASIAMOLD 2016 - 3D Printing Asia September 20-22, Guangzhou, China Loomis Products Kahlefeld GmbH 4 www.asiamold-china.com Makin Metal Powders 23 Metal AM Magazine 62 36th SENAFOR MIM2017 32 October 5-7, Porto Alegre, Brazil www.senafor.com Nanjing Hanrui Cobalt Co. Ltd. 25 POWDERMET2016 35 World PM2016 Congress & Exhibition October 9-13, Hamburg, Germany Powder Metallurgy Review Magazine 34 www.epma.com/world-pm2016 Progrit 20

Formnext powered by TCT PVA TePla 27 November 15-18, Frankfurt, Germany Renishaw 19 www.formnext.com Rio Tinto QMP 5 Ronald Britton 15 SACMI 13 POWDER METALLURGY Sunrock Ceramics 26 Advertising NO.1 VOL.1 2012 AUTUMN/FALL REVIEW To discuss advertising in Powder System 3R 28 Metallurgy Review contact: TempTAB 24 Jon Craxford, Advertising Sales Director

Tel: +44 207 1939 749 TRENDS IN HIP TECHNOLOGY United States Metal Powders, Inc. 2 DEVELOPMENTS IN PM ALUMINIUM MPIF AWARD WINNING PARTS

[email protected] Published by Inovar Communications Ltd ipmd.net World PM2016 Congress 36

…totally new perspectives

The new E-presses from the Number One in PM-technology

fast x precise x lowenergy

EP6 / EP12

WORLD RECORD Up to 200 Strokes per Minute Highest Precision

We raise the limits www.dorst.de Courtesy of AMES

Intralube® HD – the new solution for high density compaction jobs

Our latest development in press-ready mixes is called Intralube® HD – a new mix enabling higher compacted densities. What’s so good about it? This highly efficient system works most efficiently at elevated die temperatures. Through its excellent lubricity, components with even more demanding aspect n Excellent lubrication ratios or tall fill heights can be compacted. And you can use Intralube HD with n Higher green strength n Higher compacted densities lower lubricant addition to achieve even higher compacted densities. n Enables compaction of tall components In addition to these exciting possibilities, you will benefit from the well-known, n Zinc free, clean burn off overall advantages of the Intralube mix family. Such as ease of use, robust n Improved surface quality processing, clean burn off – no zinc, and low stain tendency.

Inspire industry to make more with less. www.hoganas.com/pmc