AUTOMOTIVE INDUSTRY &

POWDER METALLURGY

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 Contents
Ø Overview / Background
Ø Material Innovation at OEM
Ø Exploration Proposals
Ø Way-Forward

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Drivers for Automotive Innovations

Cost Safety

Drivers for Automotive

Innovations

Performance Comfort

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INNOVATION MANAGEMENT IN AUTO INDUSTRY
Property

Material World
Processing Performance

Gate for Materials

n
D esig
o tive t Conventional Validation Computational Analysis
om n
Aut ronm e Concept Design Concept Design
i
Env
Proto Manufacturing Digital Simulation
Physical Testing Design refinement & re-analysis
Refining design & proto manufacturing Proto manufacturing
Product Validation Product validation

Interface: Material World and Automotive Design Environment

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HIP – HOT ISOSTATIC PRESSING

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 HIP – HOT ISOSTATIC PRESSING
BENEFITS
v Consolidation of castings and powder metal parts to 100 %
theoretical density.
v Elimination of internal defects and pores.
v Increased resistance to fatigue, impact, wear and abrasion,
and improved ductility.
v Near net shape forming to precise tolerance. Little or no
secondary machining or manual rework and usually a better
surface finish.

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 WHEEL BALANCING WEIGHTS
ADVANTAGES
MATERIAL DENSITY
v Traditionally, manufactured by lead
casting. Steel 7.86 gm/cm3
Lead 11.06 gm/cm3
v Functionally superior and economical
alternative available in steel & zinc.
Zinc 7.19 gm/cm3
v PM route reduces cost of
manufacturing & assembling by 40% .

Adhesive type Clip on type

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 PISTON RINGS
Process
v Traditionally, manufactured by centrifugal or sand casting
v Disadvantage: Low yield < 90 %.
v PM route- alternate solution to cost effective
manufacturing

Close fitting flask used for Piston ring

Piston rings
casting

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 SPRAY FORMING
vSpray forming- method of casting near net shape metal
components with homogeneous microstructure via the
deposition of semi-solid sprayed droplets onto a shaped
substrate.
vRapid solidification of the sprayed droplets, resulting
spray-deposited Pre form (immediately after deposition)
characterized by a fine, uniform grain size without
macro-segregation - irrespective of the thickness of the
deposit.
vProcess particularly well suited for processing alloys
difficult (or impossible) to hot-work by conventional
ingot metallurgy.
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SPRAY FORMING – TUBES

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