german pm industry buoyant despite steep cost ramping

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special feature 12 M P R February 2006 0026-0657/06 ©2006 Elsevier Ltd. All rights reserved. German PM industry buoyant despite steep cost ramping T he Hagen PM Symposium has provided a meeting point for German-speaking experts and specialists from both industry and research for almost a quarter of centu- ry. With technical programmes aimed at stimulating interest and advances in PM technology, these symposia continue to attract growing numbers of delegates. The 24th Hagen PM Symposium held November 24-25 was no exception and Professor Bernd Kieback (Fraunhofer IFAM, Dresden) wel- comed a record number of over 230 dele- gates from 11 countries plus 60 exhibitors to the city - also a record. Organised by the Fachverband Pulvermetallurgie (FPM) on behalf of the Gemeinschaftsausschuss Pulvermetallurgie (Joint Committee on Powder Metallurgy), the theme for the 2005 event embraced "High-performance PM products" with presentations on the operational strength and applications of the high density PM and PF parts, wear resistant PM parts and hard materials, nanomaterials, MMCs, injection moulding ceramics, and PM alu- minium alloys. The annual highlight of the Hagen Symposium is the Skaupy Prize lecture which in 2005 was given by Professor Cetin Morris Sonsino (Fraunhofer-LBF, Darmstadt). The main technical programme was supplement- ed by a selection of short presentations by exhibitors on new equipment developments. Some of the key points of the programme are featured in separate reports in this issue of Metal Powder Report. In his introduction Professor Kieback referred to the continued strength of inter- est in supporting the activities of the Gemeinschaftsausschuss Pulvermetallurgie. Some 160 PM specialists are taking part in Expert Groups covering Powder Production, PM Steels, Metal Injection Moulding, and PM Aluminium, he said. Progress reports are presented at a meeting held in Hagen one day in advance of the PM Symposium. In addition, Hans Kolaska leads the FPM's Hardmetal Group which collects production statistics and coordi- nates a substantial number of co-operative research projects. Rising powder prices German PM producers are heavily reliant on customers in the domestic automotive industry. In Germany, as in France, rigid labour laws have inhibited the closure of redundant car plants, and car producers are looking to Eastern Europe and even Asia to source components in order to cut costs and remain competitive. German car production totalled 5.569 mil- lion in 2004 - an increase of 1.9 per cent over 2003. A further 4.222 million cars were produced by German companies outside Germany in 2004 - an increase of 4.6 per cent. Domestic car production was expect- ed to increase slightly in 2005 following a surge in sales in the last quarter. This surge is expected to continue into 2006 as car buy- ers make their purchases ahead of the planned 3 per cent increase in VAT to 19 per cent, which the new coalition Government will introduce on January 1, 2007. The German PM industry is weathering a generally weak economy and increases in material and energy costs with another strong performance forecast for 2005. Delegates at the Hagen Symposium were in a buoyant mood with record numbers of delegates and exhibitors attending the two-day event. Bernard Williams was there... Figure 1. Trends in German PM part and bearing production over the period 1995 to 2005. (Figures courtesy of Fachverband Pulvermetallurgie, Hagen).

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Page 1: German PM industry buoyant despite steep cost ramping

special feature

12 MPR February 2006 0026-0657/06 ©2006 Elsevier Ltd. All rights reserved.

German PM industry buoyant despite steep cost ramping

The Hagen PM Symposium hasprovided a meeting point forGerman-speaking experts andspecialists from both industry

and research for almost a quarter of centu-ry. With technical programmes aimed atstimulating interest and advances in PMtechnology, these symposia continue toattract growing numbers of delegates. The24th Hagen PM Symposium held November24-25 was no exception and Professor BerndKieback (Fraunhofer IFAM, Dresden) wel-comed a record number of over 230 dele-gates from 11 countries plus 60 exhibitors tothe city - also a record.

Organised by the FachverbandPulvermetallurgie (FPM) on behalf of theGemeinschaftsausschuss Pulvermetallurgie(Joint Committee on Powder Metallurgy),the theme for the 2005 event embraced"High-performance PM products" withpresentations on the operational strengthand applications of the high density PMand PF parts, wear resistant PM parts andhard materials, nanomaterials, MMCs,injection moulding ceramics, and PM alu-minium alloys.

The annual highlight of the HagenSymposium is the Skaupy Prize lecture whichin 2005 was given by Professor Cetin MorrisSonsino (Fraunhofer-LBF, Darmstadt). Themain technical programme was supplement-ed by a selection of short presentations byexhibitors on new equipment developments.Some of the key points of the programmeare featured in separate reports in this issueof Metal Powder Report.

In his introduction Professor Kiebackreferred to the continued strength of inter-est in supporting the activities of theGemeinschaftsausschuss Pulvermetallurgie.Some 160 PM specialists are taking part inExpert Groups covering PowderProduction, PM Steels, Metal InjectionMoulding, and PM Aluminium, he said.Progress reports are presented at a meetingheld in Hagen one day in advance of the PMSymposium. In addition, Hans Kolaskaleads the FPM's Hardmetal Group whichcollects production statistics and coordi-nates a substantial number of co-operativeresearch projects.

Rising powder prices

German PM producers are heavilyreliant on customers in the domestic

automotive industry. In Germany, as inFrance, rigid labour laws have inhibited theclosure of redundant car plants, and carproducers are looking to Eastern Europeand even Asia to source components inorder to cut costs and remain competitive.German car production totalled 5.569 mil-lion in 2004 - an increase of 1.9 per centover 2003. A further 4.222 million cars wereproduced by German companies outsideGermany in 2004 - an increase of 4.6 percent. Domestic car production was expect-ed to increase slightly in 2005 following asurge in sales in the last quarter. This surgeis expected to continue into 2006 as car buy-ers make their purchases ahead of theplanned 3 per cent increase in VAT to 19 percent, which the new coalition Governmentwill introduce on January 1, 2007.

The German PM industry is weathering a generally weak economy and increases in material and energy costs with another strong performance forecast for 2005. Delegates at the Hagen Symposium were in a buoyant mood with record numbers of delegates and exhibitors attending the two-day event. Bernard Williams was there...

Figure 1. Trends in German PM part and bearing production over the period 1995 to 2005.(Figures courtesy of Fachverband Pulvermetallurgie, Hagen).

Page 2: German PM industry buoyant despite steep cost ramping

metal-powder.net February 2006 MPR 13

Germany is expected to be overtaken asthe world's No 3 car producer by Chinawhich in 2005 was expected to make andsell 6.4 million cars, light vehicles, trucksand buses.

Dirk Hölscheid, who took over fromHans-Dieter Oelkers as managing directorof the Fachverband Pulvermetallurgie atthe beginning of 2005, told Metal PowderReport that PM part producers had toabsorb increases of up to 50 per cent in thecost of PM grade steel powders over thepast year due to escalating prices formolybdenum, nickel and copper and steelscrap. In addition the industry faced con-siderable increases in energy costs. ThePM industry has not been able to passthese extra costs on to its customers in theautomotive industry and faces a struggleto remain competitive, said Mr Hölscheid.

This is especially important where materi-al costs constitute a significant proportionof the cost of the PM component.

Mr Hölscheid stated that despite itsstruggles with energy and powder priceincreases, PM production remains buoy-ant. German PM output has almost dou-bled over the past 10 years from the 23,568metric tonnes achieved in 1995. The indus-try has enjoyed relative prosperity over thepast two years. In 2003 output in volumeterms grew by 5.1 per cent, and in 2004 ahigher growth of 6.2 per cent was achievedtaking the total to 41,732 tonnes. The2004 total represents some 435.5 millionin sales - an increase of 5.6 per cent over2003. FPM members have reported gainsin the first nine months of 2005 with ton-nage shipments up by 3.9 per cent to32,910 tonnes. Full year production was

expected to be around 44,000 tonnes whichwould be a new high.

Hans Kolaska who is responsible forthe Hardmetal Group within the FPMconfirmed that double digit growth wasachieved by the 12 German hardmetal pro-ducers during 2004. Germany is by far thelargest hardmetal producer in the extendedEU, having a market share of around 40per cent. The extended EU saw a more-than-35 per cent increase in output in 2004to an estimated 16,500 tonnes. The hard-metal market is broken down intoinserts/tools (30 per cent), rods/drills (30per cent), wear parts (25per cent), andmining/construction (15 per cent). Some34 per cent of total European hardmetalproduction is now made using submicronor ultrafine powders.

PM aluminium drives forwardin new BMW breakthroughCold isostatic pressing and pressure sinteringboth contribute to a new manufacturing processthat allows very high dimensional accuracy...

German PM part producerSchwäbische Hüttenwerke(SHW) GmbH based inWasseralfingen, reported a

breakthrough in new applications for PMaluminium parts for BMW engines at the2005 Hagen PM Symposium. Dr AngelikaPohl, manager of materials technology atSHW Automotive's PM division, told dele-gates that new components had beendeveloped for the BMW cam-phaser sys-tem in Double-VANOS (double-variablecamshaft control) used in the M3 engine.

VANOS - first introduced by BMW in1992 for its 5-Series M50 engines - is acombined hydraulic and mechanicalcamshaft control device managed by theengine management system. The device isbased on an adjustment mechanism whichmodifies the position of the intakecamshaft versus the crankshaft. Double-VANOS uses two camshafts and is said to

significantly improve torque because thevalve timing on both the intake and outletcamshafts are adjusted to the powerrequired from the engine as a function ofaccelerator pedal position and enginespeed. The weight of the camshafts is con-siderably reduced by the use of aluminiumthereby also improving fuel efficiency,reducing emissions and noise levels, andfacilitating recycling.

Dr Pohl stated that SHW uses the con-ventional press and sinter route to producea PM aluminium chain sprocket for theBMW cam-phaser system and a new PMmanufacturing process for a PM Al statorring also for the same system. For thesprocket the company uses as the startingmaterial a powder mix comprising a mas-ter alloy of Ecka Alumix 231 (Al-2.5Cu-0.5Mg-14Si) plus plain Al powder having aparticle size less than 63 µm. One per centof a special lubricant developed by SHW is

added to aid die compaction. SHW alsocoats the compacting tools with a CVDcoating of TiN/TiC because of the abra-siveness of the powder. It was stressed thatdensity variations in the sprocket must beminimised in order to maintain dimen-sional control during sintering.

Dr Pohl reported that sintering is doneunder nitrogen in a narrow time and tem-perature range (±1.5°C) and with a dewpoint of < -40°C. It is important, she said,that the oxide layer on the powder particlesis reduced during the early stages of sinter-ing to allow a liquid phase to form. Thehigh Si content is said to activate the sin-tering process. The resulting sprocketshave a sintered density of 2.65 g/cm3 and arelatively homogeneous microstructure.After heat treatment the parts have tensilestrength of up to 350 N/mm2, hardness(HB) of 95-150, and elongation of 0.5-0.6per cent. SHW uses glass shotting to