The Metal Powder Industries Federation in November elected Patrick J. McGeehan to a two-year term as the group’s president. The vice president and general manager of Ametek Specialty Metal Products spoke to Today’s Motor Vehicles about his company and the outlook for powder metals.
TMV: What powders does Ametek supply to motor vehicle producers?
PJM: Ferritic/austenitic stainless steel, tool steel, and other specialty metal powders for exhaust and engine structural applications. Powder metallurgy (PM) is a performance enhancing technology. Near-net-shape and net-shape components offer weight savings and cost-effective, customized mechanical properties.
TMV: What are the most prominsing technologies for PM growth?
PJM: Penetration of conventional press and sinter PM into automotive systems will continue to be driven by the materials’ design flexibility and cost effectiveness. Higher temperature engine applications will drive coatings developments. Use of metal injection molding (MIM) in complex 3D has been under consideration for many years. Its use for turbocharger components is a prime example. MIM, however, must be cost effective versus conventionally machined wrought components to gain further penetration.
TMV: What are the near future growth drivers for the metal powder industry?
PJM: PM solutions to complex metallurgy and high-temperature materials are driving this new look at the technology. Automotive will be targeting new lightweight materials as federal corporate average fuel economy (CAFE) standards require greater fuel efficiency from vehicles. Additive manufacturing complements both trends.
TMV: How quickly are 3D printing and additive technologies moving from prototyping to production?
PJM: There is a great deal of interest in additive manufacturing or 3D printing that is similar to the early days of MIM. Initially, the primary driver is low-volume or unique parts not suited to large capital investment that is needed for higher volume parts. Usage will be dependent on actual applications with static (non-load) having near-term prospects, while dynamic (load/rotating) applications being further off before acceptance.
TMV: What needs to happen for additive manufacturing to be viable for high automotive volumes?
PJM: Density control, dimensional stability, and available material standards/standardization are required. Currently, many competing materials and consolidation processes result in many variants to achieve the same component. Significant progress must be made on productivity/production rates for high-volume automotive applications to be possible. Cost effectiveness is directly linked to this productivity. This needs to be a major focus for both material suppliers and equipment producers.
Ametek Specialty Metal Products