Engine Products

ENGINE PRODUCTS

TM Solutions with great performance & high quality CONTENT THINK > BENEFITS OF POWDER METALLURGY

Improved wear capability 3 BENEFITS OF POWDER METALLURGY Improved thermal conductivity 4-5 PM IS AN AVENUE OF INNOVATION Tighter tolerances 6 ENGINEERING CAPABILITIES GKN Sinter Metals is the world’s largest 7 MATERIAL CAPABILITIES producer of precision powder metal products. With a focus on superior GKN ENGINE PRODUCTS delivery, quality and total solutions, we 8 ALL PM G-ROTOR PUMPS offer extensive technical expertise in design, Net shape forming testing and various process technologies. capabilities 9 BALANCER WEIGHTS Our global footprint spans more than Ability to create 10 CAM CAPS IN ALUMINIUM 13 countries across five continents. design solutions that save secondary processes 11 CAMSHAFT COMPONENTS With more than 30 global locations and more than 6,000 employees we are always 12 FORGED PM CONNECTING RODS in close proximity to our customers.

13 INJECTOR CLAMPS > 95% material utilization 14 MAIN BEARING CAPS Recycled raw materials 15 ROLLER FINGER FOLLOWER Lower energy consumption 16 START-STOP COMPONENTS ONE OF THE KEY APPL1CAT1ON AREAS OF POWDER METALLURGY (PM) 1N L1GHT VEH1CLES with reduced processes 17 TIMING GEARS ARE ENG1NE PRODUCTS. TH1S BROCHURE PROV1DES 18 TRI-OVAL PULLEYS 1NS1GHT 1NTO THE BROAD SPECTRUM OF AND SPROCKETS 1NNOVAT1VE PRODUCT SOLUT1ONS WE ARE DEVELOP1NG AND MANUFACTUR1NG HERE. 19 TURBO/SUPERCHARGER Use of lightweight MIM COMPONENTS materials

20 VALVE COMPONENTS Weight reduction capability through design (for PM) 21 VARIABLE VANE PUMP COMPONENTS

22 VARIABLE VALVE TIMING COMPONENTS

23 NOTES Elimination of secondary machining

Reduced part complexity utilizing fewer components

2 3 PM IS AN AVENUE OF INNOVATION

Living the avenue of innovation, GKN is steadily expanding the boundaries of powder metallurgy in order to open up new areas of automotive and industrial applications for powder metal. We are focusing our research and development activities in providing further unique product solutions for today and to enable life changing technologies for the future.

The world continues to change and GKN Powder Metallurgy is at the forefront of this change. With advanced forming technologies and intelligent product solutions, GKN offers technologically differentiated products.

4 5 ENGINEERING CAPABILITIES MATERIAL CAPABILITIES

ENGINEERING MATERIAL OVERVIEW

3D DESIGN • GKN‘s global engineering team • Engineered powders optimized NOTCH SENSITIVITY FREEDOM has the resources and expertise to reach mechanical and GKN has introduced a worldwide GKN‘s capabilities and experi- to optimise product design ge- magnetic properties accepted correction factor to nerating value for our customers figure out the lower notch sen- ence offers excellent opportu- • Know How on Characteristics sitivity of PM-steels. With that nities to create highly complex, • ~ 550 highly qualified of our material 3-dimensional products in pow- engineers and designers approach, the effective stress der metallurgy. Even undercuts concentration of a notch in dif- can be realised with the so- ferent materials can be predic- phosticated compaction tech- SIMULATION METROLOGY ted more realistically. Sintered nology developed by GKN. steels are less notch sensitive. • Structural mechanic simulation • B-H field meter This exceptional design free- and system design SUPPORT FACTOR • Coercimeter 4 R (M/mm2) dom enables innovative and 3 m 100 • Thermal simulation 350 • Resistance test Sintered Steel GGL 400 more efficient designs. GT 900 2 800 GGG • Electromagnetic simulation -1/0,65 400 -1/0,70 1,4 800 -1/0,75 GS 400 800 -1/0,80 1,2 STAHL 1200 -1/0,85 -1/0,90 1,1 -1/0,95 CONCLUSION: 1,04 Sintermetal DESIGN FOR PM MATERIALS & is less 2/d = notch-sensitive! ENGINE TEST BENCHES 1,02 0 • Utilise GKN‘s know-how as a 0,267 1,01 partner in product development • In-house materials test center for 0,01 0,02 0,05 0,1 0,2 0,5 1 2 5 10 tensile testing, service life tests, STRESS GRADIENT • Technology-oriented design elevated temperature testing and for cost efficient production tribological testing FATIGUE • Reduced development periods • In-house variable engine test ENDURANCE LIMIT • Added value due for performance tests, long-run The estimation of fatigue endu- to integrated functionality performance and thermal perfor- rance limits is an important OUR INNOVATION mance step for GKN for the prediction of part durability. CENTRES ADVANCED ENGINEERING POWDER METALLURGY SITES 2000 The fatigue endurance limits As an essential building block of and the scatter bands of sinte- 1800 Fe-Ni-Mo-(Mn)-C our company, the three innovati- hardened RADEVORMWALD AUBURN HILLS CINNAMINSON red steels are comparable to on centers of GKN are supporting 1600 those from conventional de- MPa the development processes of 1.400 Fe-Cu-C sign materials. They can be in- 1.300 Fe-C ALLOYED STEELS our customers. The R&D centers hardened 1.200 fluenced by density, alloying or are equipped with full size pro- 1.100 heat treatment. Fe-Cr-Mo-C 1.000 Fe-Ni-Mo-Cu-C duction facilities and advanced Fe-Ni-Cu-X-C 3%Cu 900 (hardened) materials laboratories. 800 Fe-Cu-C STRUCTURAL STEELS TENSILE STRENGTH 700 MALLEABLE STEELS Fe-Ni-Cu-Mo-C Fe-Ni-Mo-(Mn)-C The analysis and simulation ser- 600 Fe-Cr-Mo-X-C Sintered metal is light and 500 Fe-Ni-Cu-C Fe-C vice of our R&D centers covers Fe-Cu-C (hardened) Fe-P-Cu-C strong. The weight advantage of 400 GREY CAST IRON the entire life-cycle from the STRENGTH TENSILE 300 Fe-Cu-C sintered metal is based on its lo- 200 Fe-C review of the technical feasibi- 100 wer density at a comparable ten-

lity of new ideas and technolo- 6,2 6,4 6,6 6,8 7,0 7,2 7,4 7,6 7,8 sile strength. The density can be gies, up to the product develop- SINTERED MATERIALS FPM OTHER MATERIALS adjusted by customer specific (FORGED PM-MATERIALS) ment and production phase. DENSITY compaction pressure.

6 7 ALL PM G-ROTOR PUMPS PM COMPACTION BALANCER WEIGHTS PM COMPACTION

The common pump design con- siders a mix of different materials. Due to different expansion factors of each material, this ends up with some perfomance drop in case of temperature va- riations during the real driving cycle of a vehicle.

The integration of an all-PM- pump, which uses PM steel only, prevents performance loss. The expansion is uniform H1GHLY PREC1SE BORE, for all pump components and PROF1LE AND aides in better performance, sa- G-ROTOR/ STATOR PA1R MASS CONTROL ving of energy and reduction of

CO2 emissions.

KEY BENEFITS

Tailor made design according customer needs G-STATOR Long service life KEY BENEFITS

Reduced wall thickness Unparalleled design freedom for optimized Lubrication and actuation balancing and light weight pumps PUMP FACE COVER Customer expectations for smooth running and quiet engines Highly precise bore, High efficiency due have increased the need for balance shafts which are added profile and mass control to optimized clearances to engines to minimize vibration. Composite or modular balance shafts, made by assembling counterweights, drive gears and other ends up in CO2 reduction G-ROTOR Nearest to net shape design components onto a tube, offer a lightweight and competitive solu- with reduced machining Excellent hydraulic tion. operations volumetric efficiency Reduced weight variation assures balance shaft performance to offset engine vibration. Optimized geometries and tolerances assure Supplied machined PM net shape advantage accurate fit and simple assembly to the shaft and drive system. or only sized, depending reduces material waste on customer specific and machining costs requirements

8 9 CAM CAPS IN ALUMINIUM PM COMPACTION CAMSHAFT COMPONENTS PM COMPACTION

The global automotive market for camshafts has been steadily transitioning from solid cast iron camshafts to lighter weight modular assembled camshafts to optimize performance and reduce finishing costs.

PM components offer a competitive and high performance solution.

TARGET WHEEL

KEY BENEFITS

Engineered light weight product – ready to install in engine

Near net shape design – only single line boring operation needed

Designed for precise and low force installation, KEY BENEFITS removal and reinstallation Elimination of induction Integrated dowel option – hardening by one-step- eliminates costly machining sinter-hardening and dowels Camshaft caps (cam caps) are structural light weight aluminum engine components used to mount the camshaft to the cylinder Reduced finish grinding – Lower friction during cold head. They are used in internal combustion engines where in- improved dimensional startup – due to oil retention creasing demands and complexity make them ideally suited to the precision or cam lobes in controlled micro porosity PM process. Unique design solutions Unique material solutions: GKN’s PM aluminum cam caps offer unsurpassed dimensional CAM LOBES for dual profile cam designs standard, heat treated, control, strength, wear resistance and oil retention characteristics. or metal matrix composite The combination of design freedom, net shape capability and Target wheels with complex materials for increased the established performance of the PM process delivers a highly net shape geometry & strength and wear resistance competitive solution, managing logistics and ensuring simple excellent magnetic at elevated temperatures installation. material response

10 11 FORGED PM CONNECTING RODS FORGED PM INJECTOR CLAMPS PM COMPACTION

Connecting rods are key engine Fuel injected engines require components that are the link a clamp to retain the injector between the piston and the in place. PM technology has crankshaft. This allows the re- proven to be an effective and ciprocating motion resulting competitive solution for this from combustion to be conver- application. ted into the rotary motion of the crankshaft. The energy is trans- PM injector clamps are fully en- mitted through the connec- gineered products which lever- ting rod, making this a highly age advanced designs, high stressed component. strength materials and net shape capability. Forged PM technology has a long and proven track record of meeting performance and competitive requirements for many customers and applications.

KEY BENEFITS

Low reciprocating mass, high stiffness, optimized designs, efficient material utilization GKN‘S PREC1S1ON FORGED PM CONNECT1NG RODS Class-leading strength and ARE FEATUR1NG performance consistency FRACTURE SPL1T NOTCH. KEY BENEFITS due to fully homogenous alloy microstructure Engineered product – ready to install Highly consistent mass control – lowest number of Unparalleled design weight classes freedom and high strength materials to minimize size Near net shape capability and weight and fracture split notches enable for fewer finishing Optimized clamping operations contact patterns

Machinability and strength Net shape designs matched to customer requirements Heat treated if required

In house performance High accuracy validation and machinability testing No plastic deformation

12 13 MAIN BEARING CAPS PM COMPACTION ROLLER FINGER FOLLOWER MIM TECHNOLOGY

The ‘roller finger follower’ is an excellent example of how Me- tal Injection Moulding (MIM) design can integrate a variety of functions in a single component.

This part is used in the valve train of passenger cars as part of a cam follower system that is capable of shutting off a cylinder while the engine is running. Due to the high strength of the heat treated steel a lightweight design can be achieved.

GKN´S MA1N BEAR1NG CAPS ARE FEATUR1NG H1GH DENS1TY ENABLED BY ADVANCED PRESS AND CNC TOOL TECHNOLOGY.

Main Bearing caps are used in KEY BENEFITS engines to secure the crankshaft to the engine block. GKN Strength to Weight Net shape, pioneered the PM main bearing ratio better than ductile low material waste KEY BENEFITS cap (MBC) and introduced the cast iron near to net shape “ready to in- Global capability: High strength and stall” engineered MBC to the Delivered “ready to install” - manufactured in wear resistant materials market. minimal crank bore three regions machining required Complex part design By focusing on improved ma- Reduced process steps with integrated functions terials and advanced designs, Geometry optimized for compared to common GKN has helped many custo- ease of installation, technology, therefore High dimensional accuracy mers optimize their engines and removal and reinstallation higher quality aspect realize the most competitive, Optimized for minimum highest performance and ligh- In-house validation Flexible design friction and valve test weight solution. and machinability testing possibilities clearance compensation

14 15 START-STOP COMPONENTS PM COMPACTION TIMING GEARS PM COMPACTION

Start-stop technology in cars is increasingly prevalent as vehic- GKN Sinter Metals produces le manufacturers seek to reduce high-performing gears for engi-

CO2 emissions. ne applications.

Ring gears ars one of the main With the specific "design for components of the gear set in PM" approach the manufactu- the starter motor and are typi- ring process is significantly re- cally made from plastic. Within duced, limiting the need for ma- the start-stop technology gears chining, energy and waste. need to be stronger and more durable to withstand more fre- quent stress.

Creating the ring gears from powder metal provides a lightweight, high-performing solu- PLANETARY GEAR SET tion, which is more resistant to wear and can achieve tighter tolerances. PLANETARY GEAR R1NG GEAR

KEY BENEFITS

Reduced noise, vibration harshness (NVH)

Net shape or near to net shape designs save machining at customers.

KEY BENEFITS Tailor-made PM design with multipart substitution Low friction surfaces and downsizing

Best net shape tolerances Enables light weight solutions High densitiy & torque perfomance Easy to assemble zero backlash solution due Custom-tailored tooth to reduction in the number spline geometry of parts MA1N P1N1ON

16 17 TRI-OVAL PULLEYS AND SPROCKETS PM COMPACTION TURBO/SUPERCHARGER MIM COMPONENTS MIM TECHNOLOGY

VANE LEVER UN1QUE GEOMETRY ENABLE BY PM REDUCES NVH

VANE

ADJUSTMENT R1NGS Pulleys and sprockets are typically used in engines to drive crankshaft and camshaft timing systems. Complex geometry makes these products PULLEY an ideal application for PM technology. Variable geometry turbochargers (VGT’s) are designed to allow the Net or near net shape teeth, SPROCKET aspect ratio of the system to ad- weight reduction features and just to the optimum pitch depen- integrated drive features gives ding on engine speeds. PM an advantage over other KEY BENEFITS metal working processes. 1MPELLER A key component in this system KEY BENEFITS Near net shape is a ring of aerodynamically- With decades of design, en- capabilities - only minor shaped, movable vanes in the gineering and manufacturing Net shape designs Induction hardened or low machining required housing at the turbine inlet. experience combined with optimize light weighting distortion sinter hardened advanced process and ma- options Unique high temperature Complex geometry combined terial solutions, GKN has hel- Design freedom facilitates corrosion and wear resistant with a high temperature corrosi- ped many customers optimize unique net shape features Unique joining technology materials ve environment are ideally mat- their product designs accor- such as lightening holes facilitates the addition ched to the shape and materials ding to the specific application and drive features like of stamped flanges Proven manufacturing capabilities of the Metal Injection requirements. keys, keyways and slots or sensor rings capability Molding (MIM) process.

18 19 VALVE COMPONENTS PM COMPACTION VARIABLE VANE PUMP COMPONENTS PM COMPACTION

KEY BENEFITS Valve Guides: PM has proven to be the excellent solution for valve Variable vane pumps can be guides through the combination of unique wear resistant and self- adjusted so that the out- Unique materials combine lubricating materials, which provides an optimal combination of put is adapted to application excellent valve lubrication wear & scuffing resistance, lubrication and machinability. Inher- demands. This allows for im- and machinability ent porosity helps in oil retention giving additional lubricity and proved efficiency and lower reduced wear. energy consumption. Improved wear and scuffing resistance Due to the complex geometry and requirements for high pre- Improved lubrication by cision and performance, PM filling micro-porosity with oil technology has proven to be an by vacuum impregnation ideal manufacturing solution for Near net shape – only mini- HOUS1NG many challenging applications. mal finish machining required GKN supplies rotors, vanes and housing components and works VALVE GU1DES on all PM pump solutions.

DUAL MATER1AL COMPACT1ON PRESS1NG TECHNOLOGY ALLOWS VANE H1GH ALLOY MATER1AL 1N KEY BENEFITS VALVE SEAT1NG AREA AND

LEAN ALLOY MATER1AL Unique materials combine excellent machinability, AT BOTTOM. thermal conductivity and wear resistance

Dual material compaction KEY BENEFITS technology allows high ROTOR alloy material in valve seating Improved surface tribology area and lean alloy material VALVE SEAT 1NSERTS at bottom, providing both Net shape vane geometry higher performance and cost optimization Reduced energy Fully dense matrix by copper consumption infiltration enhances thermal properties and machinability All PM version Valve Seat Inserts: PM provides the possibility of combining vari- for highest efficiency High material utilization ous alloy systems which allows application specific solutions ran- through near net shape ging from 80cc engine to as high as 17.0L engine. Wear resistance Material & hardness capability which requires at high temperatures, excellent thermal properties and very good custom-tailored to match minimal finish machining machinability are the major advantages of PM valve seat inserts. performance requirements

20 21 VARIABLE VALVE TIMING COMPONENTS PM COMPACTION NOTES

In order to achieve requirements COMB1NED VVT SPROCKET- to reduce both automotive fuel STATOR consumption and CO2 emissions, while also increasing performance, systems that optimize camshaft or valve timing are of increasing importance.

PM has proven to be an ideal solution for variable cam timing (VCT) and variable valve timing (VVT) components by facilita- ting freedom of design and de- livering highly precise, complex products.

KEY BENEFITS

Best net shape accuracy

Compact light weight ROTOR VVT designs

Reduced machining with multi part design

Low friction with STATOR VVT custom surface geometry

Proven dimensional precision reduces internal oil losses

Unique machining process simplifies deburring

Induction hardened or low distortion sinter- hardened sprockets

ROTOR VVT 22 23 GLOBAL SALES OFFICES

GKN Locations AMERICAS EUROPE USA UNITED KINGDOM 2200 N. Opdyke Road PO Box 55. Redditch Over 30 locations Auburn Hills, MI 48326-2431, USA Worcestershire, B98 0TL, England in 13 countries MEXICO GERMANY New production location Krebsöge 10 on 4 continents SOP 2019 42 477 Radevormwald, Germany BRAZIL ITALY Av. Emancipação, 4.500 Fabrikstraße 5 CEP 13186-542 39 031 Bruneck (BZ), Italy For specific details and contact Hortolandia – SP, Brazil [email protected] information please write to us ASIA SWEDEN at contactpm@gkn.com or visit CHINA Mölndal, Sweden Suite 1105-1110, POS Plaza P.O. Box 186, SE-431 23 our website www.gknpm.com 1600 Century Avenue Mölndal, Sweden Pudong, Shanghai 200122, China [email protected] INDIA FRANCE 146 Mumbai - Pune Road 6 Lotissement les Cruzettes Pimpri, Pune 411018 38210 Tullins, France Maharashtra, India TURKEY JAPAN Istanbul Ataturk Havalimani serbest bolgesi Senri Life Science Center Bldg.10F L Blok No:2 1-4-2 ShinSenri Higashi-machi 34149 Yesilkoy-Istanbul/Turkey Toyonaka-city, Osaka, 560-0082 Japan