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Abstract: Powder metallurgy (PM) is primarily used because of its relatively close capability and cost-achievement
ratio. The automotive industry is a major market for the powder metallurgy industry, as it necessitates products having
superior mechanical or part of the implementation on a global level. PM technology is undergoing considerable changes
in manufacturing and materials research as automobile technologies transitions beyond classic gasoline - powered
vehicles to new energy vehicles. Changes in automobile technologies has created both obstacles and opportunities for
PM, as outlined in this article. Future PM materials development will need to be relatively inexpensive, more efficient,
and having less than average weight. As a result, research into Powder metallurgy lean-alloyed steel, aluminium alloys,
and nickel - titanium materials were looked into. Additionally, the use of Powder metallurgy soft magnetic compound in
clean, renewable energy transports has been considered. Now there are significant potential for sophisticated systems in
the automobile industry, which including injection moulding (MIM) & additive manufacturing techniques (AM). In
general, the automobile community's transformation provides sufficient development opportunity for PM. Emerging
innovations, on the other hand, need the use of progressively superior PM materials. Because of their mechanical
performance and inexpensive cost, steel parts have always been the most popular Powder metallurgy compounds. MIM
will enter the rapidly expanding industry for highly flexible and complicated products. AM allows for quick prototyping,
high flexibility, and low-cost customization, as well as weight and assembly savings.
Keywords. Powder metallurgy; metal injection molding, additive manufacturing; automobile; lean alloy; Al alloy; ,
Composite
INTRODUCTION
Advantages of PM technology
Powder metallurgy is the conversion of metal powders into usable technical compounds [1]. The
primary advantage of PM is that It allows you to mass create components with high dimensional precision
and mechanical qualities in a cost-effective manner, you require at a cheap cost and with minimal waste. Iron
ores were used to produce implements by the Egyptians in 3000 BC, which gave rise to PM technology.
The automotive industry's early interest in mass-produced things allowed for massive quantities of
iron and copper powders to be used, sparking many of the current PM sector's technological advancements.
In 1927, In the first commercial application, a self-lubricating bearing consisting of copper and tin . PM
product with granules was used in an automotive application. [2]. As structural components, PM materials
have improved quickly in recent years, with sintered steels now having properties comparable to wrought
steels, as shown in Figure 1 [3].
Because the majority of manufacturing processes involve energy and natural resources, Greener raw
materials and manufacturing processes are becoming more popular.. Because of its high material utilisation
and low usage of energy.PM is considered an environmentally benign process. An injection molded yoke
utilized in A Life Cycle Assessment was performed on a heavy truck application. (LCA) by ENGSTRM et al
[4].
FIGURE 1. Tensile strength comparison between PM and other steel materials
For a common car component, one purpose was to compare the environmental impact of machining and
forging to PM technology. Another objective was to investigate the environmental impact of two
different PM materials. Figure 2,3,4 shows that PM has an environmental advantage over wrought steel
because it uses less energy, and the Cr-containing PM material outperforms the Ni-containing PM
material. PM technology has made considerable advances in previously thought-to-be difficult sectors
during the last few decades. This favorable trend is being driven by improved mechanical performance,
tighter dimensional tolerances, and cost-effective methods.
Climate change potential (GWP), ozone depletion productivities (POCP), acidification potential (AP), &
eutrophication prospect (EP) are all measures of environmental effect (EP). The comparison between these
two Powder metallurgies, materials reveal that Astaloy (CrM), a chromium-including material, has a lower
impact on the environment than Distaloy AE, a nickel-molybdenum-copper.
The high Ni concentration of Distaloy AE accounts for the higher number. When creating high-
performance components, the LCA evaluation shows the environmental advantages of PM technologies over
traditional maded steel technology. The results also demonstrate that employing Cr alloy steels PM material
rather than large Ni content has advantages. In 2017, China's total steel powdered industry sales volume
exceeded 553 kt, with an annual increase of 10% through the previous ten years. Parts for various portions in
vehicle & motorbike industries accounted for 53.2 percent of total volume [5]. The explosive growth of
China's automotive industry, and also enhanced metallic powder development in association with new
production equipment development in compression tooling, presses, and sintered furnaces, has enabled these
accomplishments.
FIGURE 5. Volume and growth rate of vehicle sales in China from 1994 to 2016.
Figure 6 [7] shows a published forecast for future propulsion technology penetrations. Full electric
and hybrid vehicles have been identified as key technology for meeting future emission regulations, with
traditional vehicles' hydraulic, transmission, and engine systems containing many PM parts shrinking and
eventually disappearing. The speed and completeness of this change, on the other hand, are far from clear. In
the next 15 years, significant expansion in electrification is projected. Given the PM industry's reliance on
the automobile market, the potential impact of each technical change in the automotive sector must be
carefully analyzed.
FIGURE 5. Transmission type forecast.
In the long run, the transition from traditional combustion engines to hybrids or purely electric
vehicles will offer considerable difficulties to the PM fields. Clearly, change will not occur anytime soon.
The PM field is so well prepared to continue developing solutions that enhance efficiency in traditional
powertrains while also capitalizing on future electric and hybrid system opportunities. However, as
demonstrated in Figure 6, China's average use of PM parts per automobile has been just 3.96 kg, even less
than European or American [8]. It demonstrates that its Chinese powder metallurgy industry still has a
technical deficit, as well as a lot of space & possibility of growth within market place .
FIGURE 6. In different countries and locations, the average number of powder metallurgy parts used per automobile.
PM ALLOYS
New ferrous alloys for PM
Several ferrous alloy systems, which include iron/carbon (Fe-C), copper/carbon -iron (Fe,Cu,C),
astaloy steel, made by mixing low alloy steel, heat treated hard materials, as well as distribution alloy steels
steel, have indeed been normalized through PM formation manufacturing techniques, going to cover a
detailed materials platform from minimum to maximum strength [9].
Conventional molybdenum or nickel alloying elements, on the other hand, are often utilized as
alloying with small powder metallurgy steel for improving the strength and hardness and strength of
composite PM products. In recent times, the dramatic unpredictability of these materials' prices had also put
more pressure on cost and lower profit throughout the entire value, leaving PM techniques lesser economical
especially compared to alternative manufacturing processes like forging and casting. Figure 7 depicts the
price evolution of these metal components in comparison to Cr from 2015 - 2018 [10]. As a consequence,
there's also a significant focus on enhancing mechanical qualities with much more cost-successful and far
less reactive alloy solutions. Respectively high strength and hardness and high density should be used to
produce mechanical characteristics equal to wrought steel.
Aside from alloying content, the sintering method, in association with the processing
temperature(cooling), determines the strength. Different heat treatment process, including hardness or case
surface hardening (carburizing), can boost the toughness even more. To avoid excessive shrinkage during
sintering, the density is most important, which is better accomplished immediately via compressed air or hot
compaction.
FIGURE 7. Metal and raw material prices have fluctuated throughout history.
Employing local densifying techniques like surface rolled, cold work process (shot peening), the density can
be raised even further in subsequent processing procedures [11, 12]. To date, dispersion powders containing
mixtures copper Ions, Ni, & Mo, as well as purified & developing high iron powder & Mo astaloy powders,
are the most widely utilized materials for rising application. Cr and Mn as alloying elements have recently
been studied [1315]. The alloying components Cr and Mn give hardenability and strength while remaining
cost effective. Cr and Mn elements, on the other hand, are prone to oxidation. A considerable increase in
strength can be produced by using (astaloy) pre-alloyed Chromium powders in addition to high temperatures
sintered, especially >1210 °C [16].
Table1 lists a few commercially available high-performance PM steels &table 1 shows the mechanical
characteristics at 1120°C for traditional sintering and 1250°C for high sintering. It is obvious that sintering at
a high temperature is helpful to high strength. Tensile is between 520 & 800 MPa following sintering at 1120
°C, and between 800 and 1100 MPa following sintering at 1250 °C.
TABLE 1. shows the mechanical parameters of the material after 600 MPa compaction and 30 minutes of sintering at
1120 °C and 1250 °Respectively, with a cooling rate of 0.51.0 °C/s as a preventative measure atmospheric 90 N2+10 H2.
1120 °C 1250C 1120 °C 1250 °C 1120 °C 1250 °C 1120 °C 1250 °C 1120 °C 1250 °C
Distaloy AE
751 1051 422 722 221 302 2.4 1.4 −0.13 −0.81
0,( 5%C)
Distaloy HP
831 1102 505 801 282 351 1.4 1.4 −0.14 −0.84
( 0. 5%C)
Astaloy CrM
802 1101 601 852 244 311 1.2 2.1 −0.21 −0.74
(0, 4%C)
Aluminium alloys is used in a variety of vehicle industries. Metallic powder product Co (MPP) &
GKN hard materials metal, for example, have been producing and using cam caps successfully since 1993
[22]. Using typical gas atomization, Al alloy powder can be easily manufactured. Fully pre-alloyed Al
powders, on the other hand, are rarely employed due to their low compaction and sintered activity. Particle
mixing methods are developed and precisely engineered in order to obtain the best feasible press&sinter
performance for adequate mechanical, microstructural, and physical qualities. For introducing alloying
elements, highly finest elements particles (usually 46 m) with binaries pre-alloyed powder with a nearly
austenite phase (e.g., AlSi12) including up than 50% AL was utilized.
In PM Al manufacture, sintered is considered as the most significant step. The oxide coating on the
surface of the Al powder inhibits the Al powder particles from sintered. Cu-containing hydrate sintering is
one possible solution. During sintering, Cu can create a liquid phase along Al, disrupting the stable oxide
layer. The hypereutectic .5Mg-2.5Cu-Al-14Si alloy as well as the 1.7Cu-2.5Mg-Al-6Zn alloy produced in
ECKA, Bavaria, are examples of transient liquid phase sintering systems. Powder metallurgy of Al parts are
now typically employed throughout minimal applications requiring fabrication shaping. PM Al alloys have
higher mechanical properties than cast alloys but poorer mechanical properties than as-wrought alloys.
Existing powder metallurgy of Al compounds are unable to satisfy the demands of new applications with
high elasticity, fatigue strength, or thermal property stability at elevated temperatures [23]. As a result,
additional research is required to develop a wide variety of quality powder metallurgy of Al alloys
appropriate for middle to high tensile grade purposes. For PM Al alloys, heat treatment is an important
aspect in achieving a high level of mechanical property [24],[25].
3-dimensional formed components by Powder metallurgy method. SMC could offer significant advantages
with 3D shape, configuration via Powder metallurgy as compared to standard laminated electrical steel. In
drive systems, pumping systems, ignitions system, regular diesel injector systems, reactor for DC-DC
converter, e-turbo mechanism, and AC compressor, SMC will have a lot of promise. Figure 8 depicts some
of the most common uses for SMCs[28].
It's worth noting that the most obvious benefit of employing SMC in linear machines is from a
production standpoint. By switching from lamination to SMC, the number of parts can be reduced and
assembly can be simplified, as shown in Figure 9. Furthermore, by altering the design for SMC, the
performance may be not only equalled but substantially improved[30],[31],[32].
FIGURE 7. SMCs have advantages and disadvantages over electrical steel [33].
Advantage Disadvantages
Three-dimensional shaping is more complicated than Mechanical strength is lower than that of electrical
sheet metal cutting. steel.
Thermal properties that are quasi-isotropic Magnetic characteristics are influenced by density
differences.
CONCLUSION
Because of environmental friendliness, higher manufacturing utilization, & reduced energy consumption,
PM is not only a low cost along-net shaping process, and also an environmentally benign technique. PM
technology has advanced fast in tandem with the growth of the vehicle industry. Alternative manufacturing
processes pose a few competitive risks as automotive technology changes beyond combustion to electric
vehicles, although these transitions will take time. In order to produce a product, process and material needs,
PM technology will undergo substantial modifications.
The possibilities for materials with low cost, excellent performance, and low weight will always be
available. In light of these considerations, PM ferrous steel, Al, and Ti alloys materials face significant
hurdles and technological advancements. Soft magnetic composite materials will open up a slew of new
possibilities, while certain applications are already in place. It is envisaged that MIM and AM will be able to
get chances in the new design of complicated ge ometric components, assuming that the limitations of these
technologies, such as tolerance, size, and cost effectiveness, are solved .
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