New Pastures for Metal Powder Industry

Powder metal companies that focus on the auto industry have been suffering declining shipments, but many non-automotive niches are doing well as engineers tap the design advantages of powder metal.

Meanwhile, overseas markets such as China and India are showing an increasing appetite for powder metal parts. Research is moving ahead, too, on new processes that could open up new applications for powder metal.

These are some observations from Metal Powder Industries Association Executive Director James Trombino, who recently answered questions on his industry’s outlook for Design News.

Design News : What is the powder metal industry doing to cope in the face of slumping business in its prime market, automotive?

James Trombino: For one thing, we’re continuing to promote the engineering benefits of PM to end markets outside automotive. We do this through market development and educational programs, such as the annual design competition where we recognize outstanding PM applications. Other steps we are taking include updating materials standards and promoting the new Global PM Property Database, a collaboration with our European and Asian counterparts. To further promote PM’s advantages to the auto industry, MPIF is embarking on an ambitious market development program where the industry puts on full-day showcases at various OEM locations.

DN: What application areas beyond automotive are showing the most promise for PM applications?

JT: Some of the most promising end markets beyond automotive include electronics, recreational vehicles, medical/surgical equipment and farm equipment.

DN: To what extent are expanding global markets helping to offset the slump in some parts of the PM market in the U.S.?

JT: North American PM companies are building offshore plants in Asia, following their customers who have assembly plants in the region, especially in China. PM is expanding very rapidly in China, India and Korea, where the PM parts market is growing at double-digit rates. The typical passenger car built in China, for example, contains about ten pounds of PM parts. MPIF has sponsored successful trade missions to China and India. The most recent mission to India was in February 2007. MPIF member companies visited with major automotive and home appliance companies.

DN: The metal injection molding sector seems to be a bright spot. What is driving the increased interest in that field?

JT: Metal injection molding (MIM) offers some very unique design benefits, combining strength with very intricate and complex shapes. Major markets are mobile phones, computers and laptops, and medical, dental and surgical applications.  The international MIM market is enjoying double-digit growth rates and accounted for more than 50,000 tons of raw materials last year. Overall, the Metal Injection Molding Association estimated the total international market for MIM at $435 million in 2006, although some observers say the global market is much higher.

DN: What are some of the new PM applications that will open up as the result of the development of new processes and powders?

JT: New high-density processes will open up more high-strength applications in auto transmissions and engines. PM companies, including parts makers, metal powder producers and equipment suppliers, are working together to achieve densities of 7.5 grams per cubic centimeter and higher in a single-pressing/single-sintering operation. PM can provide mechanical properties that approach or match those of wrought materials and sometimes even exceed wrought materials. High-strength PM parts, such as automotive connecting rods, have been successfully used in auto engines for more than 20 years. Nonferrous powder producers are also developing new materials such as super high-strength bronze alloys for PM gears.

DN: Can you cite a couple key programs of the Center for Powder Metal Technology that are aimed at boosting the industry's capabilities?

JT: Among the Center’s ongoing research initiatives, it has launched its most ambitious program to date, focusing on achieving “full density” in a single pressing operation. This program is funded by CPMT and through a consortium of companies that have raised over $200,000. The first phase of the program is targeting high-velocity compacting, warm compaction, and ultra-high-pressure compaction. A corollary program in admixed lubrication and die-wall lubrication has also been launched.

DN: How would you assess the average design engineer's knowledge of PM technology?

JT: The average design engineer may not fully understand the PM process, both the advantages and the limitations, and how to best apply the process. PM must be understood in terms of its material properties, tooling design and processing. However, engineers who look into PM’s capabilities will find that this technology competes most effectively with castings and machined parts that require extensive secondary operations. As a net- or near-net-shape manufacturing process, PM offers substantial cost savings by eliminating processing steps and assembly operations.