Review: IPMD 14th Edition 2010-2011, 24 pages, 10186 words

Author: Bernard Williams, Consultant, Shrewsbury, UK

Unique and exclusive to the IPMD is the 24 page ‘IPMD PM Global Market Review’ which analyses trends in the various sectors of the PM industry – globally and regionally. The review has been compiled by Bernard Williams, former Executive Director of the European Powder Metallurgy Association.

Also includes two extra features:

• MIM Focus: Metal Injection Moulding (MIM) growth slows in 2009
• Automotive Focus: Global recession hits auto output

Bernard Williams has charted the recent economic turbulence as reflected in some of the key statistics in regional and global shipments relating to ferrous and non-ferrous PM products, hardmetals, diamond tools, PM semi-products and powder-based magnets. Two inset features review PM’s special relationship with the automotive industry and the growing end user acceptance of metal injection moulding.

This ‘Global Market Review’ is also published in the 14th Edition IPMD.

Introduction

Powder metallurgy (PM) is an advanced manufacturing technology used for producing a wide range of finished and semi-finished engineering components. PM can be used for processing practically all types of metals and alloys in powder form which are consolidated into final or near-near shapes by a variety of processes. These include die compaction, injection moulding, isostatic pressing, forging and extrusion. The different methods of consolidation help to achieve the desired complexity of shape, density and properties required in the final PM component. Sintering after consolidation of the powder is usually done at a temperature below the melting point of the main constituent metal and gives the component its strength through the metallurgical bonding of the powder particles. Some components are hot pressed to achieve simultaneous densification and metallurgical bonding.

Although PM has been used since the 1920s for products such as hardmetal (cemented carbide) cutting tools and oil retaining porous bearings, it did not come into its own as a competitive mass production technology for structural PM parts and other advanced PM products until the 1970s and 1980s.

Over the past three decades, the growing number of new structural engineering applications for PM have included high strength, high density PM parts, high performance PM bearings, intricate parts made by metal injection moulding, sintered hard materials for cutting tools and wear parts, ultrahard diamond tools, powder-based magnets, sintered filters and other porous products, lamp filaments, capacitors, electrical contacts, carbon brushes, friction materials and PM semi-products such as tool steels, refractory metals, superalloys, etc. They have all helped PM to become the fastest growing metal forming technology with annual global sales for all sectors exceeding an estimated $27 billion in 2008, although this estimate will have been severely dented by the global recession in 2009.......

Further sections of this article include:

• Manufacturing takes a hit as the global economy dives into recession
• Market sectors for PM materials
  - Ferrous PM Materials
  - High Alloy PM Steels
  - Copper and Copper-base
  - Cobalt
  - Tungsten
  - Molybdenum
  - Tantalum
  - Niobium/Rhenium
  - Hardmetals/Cemented Carbides
  - Diamond Tools/CBN Tools
  - Powder-based Magnets
• Regional markets
  - North America
  - Europe
  - Asia/Oceania
• References
• Acknowledgements

Figures and Tables:

Fig. 1 Trends in global PM grade iron, steel & stainless steel powder shipments (mt) 2001- 2009, plus inset showing regional market share

Fig. 2 Trends in global PM grade copper & Cu-base powder shipments (mt) 2000-2008, plus inset showing regional market share

Fig. 3 Applications for PM structural parts by world region in 2008

Fig. 4 Breakdown of global PM based refractory metals market

Fig. 5 Breakdown of global PM based refractory metals applications

Fig. 6 Global hardmetal (cemented carbide) production 2008.

Fig. 7 Cemented carbide production in Japan, tonnes and sales 2001-2008. Courtesy Japan Cemented Carbide Tool Manufacturers’ Association

Fig. 8 Hardmetal consumption by world region 2006-2008, in tones tungsten (Courtesy H.C. Starck Market Research, May 2009)

Fig. 9 Global sintered NdFeB magnet production (mt) - 2008

Fig. 10 Market share of sintered NdFeB magnet production in China, 2008 (Source: Prof. Yang Luo, IEEE TC-15 Voting Member)

Fig. 11 European PM production was estimated at €8.25 billion in 2008

Fig. 12 Breakdown of PM production in Italy, 2008

Fig. 13 Market share of PM parts production in Asia/Oceania, 2008

Table 1 Global PM production by sales value

Table 2 Global economic trends 2007-2011 (Source: World Bank)

Table 3 Fluctuations in some of the key metal commodity prices used in PM in the period 2005-2009

Table 4 Global Shipments of PM ferrous powders including stainless steel 2001-2009

Table 5 Trends in worldwide production of high alloy PM steels by HIP

Table 6 Global shipments of copper and copper-base powders – 2000-2008

Table 7 Trends in refractory metals production for PM-based products 2007-2008

Table 8 Estimated worldwide production of NdFeB sintered magnets [14]. (Data presented by Prof. Yang Luo, REPM 2008)

Table 9 North American Powder Shipments (short tons) for all applications 2000 - 2006 (Source: MPIF, Princeton, NJ)

Table 10 European powder shipments for PM 2002-2008

Table 11 Ferrous PM part production in Germany 2001-2009. (Source: Fachverband Pulvermetallurgie, Hagen, Germany)

Table 12 PM Part and bearing production in Italy (Source: Assinter, Italy)

Table 13 Estimates of PM Part Production in CIS Countries and Turkey

Table 14 PM Production in Asia and Oceania - 2002 to 2008

Table 15 Iron & steel powder production Japan 2001-2008

Table 16 Powder Shipments in Japan for PM Applications 2002-2008

Table 17 Structural PM part production in China (Data published by China Machine Parts Association – Powder Metallurgy Industries & Enterprises)

Special Feature: MIM Focus

Metal Injection Moulding (MIM) growth slows in 2009

Metal injection moulding (MIM) combines the long established plastics injection moulding process with powder metallurgy to produce highly intricate shapes having the desired high strength of metals, excellent dimensional control and surface finish and if needed, corrosion resistance and biocompatibility. MIM technology involves mixing fine metal or alloy powders with a thermoplastic binder to produce a feedstock which can be injection moulded into a tool cavity followed by thermal processing to remove the binder and finally sintering the remaining metal powder compact. Densities of 95% or higher can be achieved after sintering and for that reason the mechanical properties of MIM parts are generally superior to traditional die compacted and sintered PM parts......

Figures and Tables:

Fig. 1 Application areas for MIM components in Europe, Asia and USA

Fig. 2 Growth in global MIM powder shipments 2002-2008

Fig. 3 Global market share for MIM powders based on tonnage shipped

Fig. 4 Breakdown of MIM materials according to region

Fig. 5 Applications for MIM parts in Japan, 2008. Courtesy JPMA

Table 1 Global estimated MIM (metal and carbide) sales 2004-2008

Table 2 Breakdown of MIM (metal and carbide) sales in Asia 2008

Table 3 Forecast Global sales of MIM products by region

Special Feature: Automotive focus

Global recession hits auto output

The PM industry, whether it be structural PM parts, carbide tools, sintered magnets, or self lubricating bearings, has for several decades and will be in the foreseeable future, heavily reliant on the automotive sector. In the case of Japan, more than 90% of structural PM parts find their way into vehicles whilst in Europe it is over 80% and in N. America it exceeds 70%. Therefore, any major fluctuations in the fortunes of the world’s automotive producers will directly impact on the fortunes of the global PM industry......

Figures and Tables:

Fig. 1 Application breakdown of PM parts and PM bearings used in Japanese cars (Courtesy JPMA)

Fig. 2 World motor vehicle production (%share) 2008. (Source: ACEA)

Fig. 3 Car sales according to CO2 emissions in Europe

Fig. 4 Growth in EU demand for cars with CO2 emissions <120 g/km

Fig. 5 Toyota Prius Hybrid powertrain (Courtesy Toyoto Motor Corp.)

Table 1 World motor vehicle production by region – 2005-2008 (Source: International Organisation of Motor Vehicle Manufacturers – OICA)

Table 2 Average weight of PM parts used in cars