Submitted To: Prepared By:

Dr. V. J. Rao Milan Mungala(370)

Associate Professor (Industrial Metallurgy)

Department of Metallurgical & Materials Engineering

Faculty of Technology and Engineering
The Maharaja Sayajirao University of Baroda
Vadodara– 390001, Gujarat
1
• Introduction
• PM Structural Components Market
• PM Processing Techniques
• Use of PM in automobile sector
• PM parts
• Materials
• Conclusion
2
• Powder metallurgy is an established green manufacturing
technology for the production of near net-shape components.
• The ability to use PM to mass produce precision parts at a
cheap rate is very attractive to the automotive industry.
• Automobile manufacturers are facing the challenge of
procuring components with light weight, superior
performance and enhanced durability and reliability in
order to produce comfortable, safe vehicles at low cost.

3
• PM is an energy saving, green technology offering
improved performance and greater design flexibility
compared with manufacturing methods such as
casting, extrusion, forging, stamping and machining.
• Over 70% of powder metallurgy production
worldwide is aimed at automobile manufacturing
sector
• There is scope for P/M in automobile industry,
considering the wide variety of vehicles such as cars,
buses, trucks, vans, scooters and motor-cycles.

4
5
• Many P/M processing techniques are available
like:
a)Pressing and Sintering
b)Hot Isostatic Pressing
c)Powder Forging
d)Metal Injection Moulding
e)Rapid Prototyping
6
• Sintered self lubricating bearings
• Low density structural parts
• Shock absorbing components
• Timing gear,
• synchronizer hubs, valve seats
• belt pulleys and power steering parts
• connecting rods, composite cam shafts and emission control
system parts
• the current level of more than 1000 parts with 300 different
applications, weighing 30 to 45 kg depending on the type of
application. 7
• The use of P/M in automotive vehicles such as
cars, buses, trucks, vans and so on can be
classified into transmission, engine, cases and
other components.
• Some P/M parts such as bearings and gears are
common to all vehicles, although their size,
strength, geometry and function may vary
depending on their specific application.

8
9
10
* The mass production parts of scooters and motor-
cycles:

Scooter/ motor cycle parts

11
• Automotive transmission can be manual, semi-
automatic, automatic or use variable valve
timing.
• The parts used in manual transmissions are :
- synchronizer hub, blocking ring,
- interlock sleeve, gear shift lever,
- synchronizer plate,
- clutch hub, clutch release hub, detent lever,
guide plate, etc.
12
 * Some of these parts are shown in figure:

Gear box/transmission (clutch hub, gear shifting yokes etc.)

13
*In automatic transmission different parts like
- vane-type and gear type pumps,
- the converter turbine hub,
- converter clutches, chain sprockets etc. are used.
*Hubs, races, clutch plates and carriers are all
important components in automatic transmissions
that are manufactured using PM.
*Individual PM parts are joined by brazing or welding
with tight tolerances.

14
* The assembled parts and their carriers are shown in
figure:

(a) Assembled components

(b) Individual PM parts
(c) 2-piece carrier brazed
(d) 3-piece carrier welded

15
• PM has played an important role in the development of
new engines,
- either by improving existing components
or
- by improving the design possibilities of
components in newly developed systems.

• The use of PM components has improved engine

performance, as well as reducing costs.

16
17
*PM technology has allowed for the use of cams and
intermediate rings on a hollow tube,
*Resulting in dimensional precision, stringent wear
resistance and a lighter assembly.

Composite cam shaft

18
*Powder forged connecting rods have much tighter
tolerances and the rod’s main bearing head has
resulted in improved balance in the engines.

Connecting Rods
19
* The use of PM technology has also helped to reduce the
weight of distribution pulleys as shown in figure

Distribution pulleys
20
*The transition from carburettor to gasoline fuel injection
systems has resulted in a reduction in fuel consumption and
emissions.
*Fuel injection pump parts and Soft PM magnets are used in
the injectors, as shown in figure.

Soft magnetic materials for

Fuel injection pump parts
gasoline injection system
21
 Power Steering parts

Engine and synchronizer stainless steel MIM parts:

(a)Engine valve seat
(b)Engine filter
(c)Shock absorber parts
22
Shock absorber parts Seat reclining parts

23
• A variety of iron, steel, alloy steels, stainless
steels, copper, bronze, aluminium and titanium
alloys and composites are used for automotive
components, in addition to electrical, magnetic
and electronic materials.
• The general trend is to reduce weight, increase
strength, improve the net shape, utilize heat
treatment and special surface treatments and
improve precision in transportation.
24
*In connecting rod are most usually
made of steel for engines.
*But can be made of T6-2024
&T651-7075 type aluminum alloy
for lightness & ability to absorb
high impact or titanium for
combination of lightness with
strength.

25
*Al alloy part are used to reduce the weight and
increase the fuel efficiency of the vehicle.
*For ex. – cam shaft–bearing cap, pulley, oil pump
rotors, cylinder liner and shock absorber part.
*Al-Si, Al-Cu-Mg, Al-Zn-Mg-Cu, Al-Cu-Si-Mg, Al-Fe-C
alloys are used for these application.

* Titanium is another metal with low density, high

strength and good corrosion resistance.
*For ex. – inlet valve , timing pulley, fuel pump filters
has been established from Ti-6Al-4V using elemental
and alloy powders. 26
*Cu alloys such as bronze and brass, and the bearing
alloys, Cu-Sn, Cu-Zn, Cu-Pb-Sn & Fe-Cu-Pb-C are used
in large numbers for self-lubricating brushing, brushing,
filters, brake bands, clutch segments, locks and keys.
*Cu-C material are used in motors, starters, voltage
regulator, circuit protectors, relays and contact brushes.

27
• Powder metallurgy is a sustainable manufacturing technology
for the mass production of precision engineering components
using a wide variety of materials.
• It is increasingly attracting the attention of the automotive
industry.
• The automotive industry has undergone substantial changes
in terms of increased performance, reduced fuel
consumption, environmental impact and improved safety.
• PM has played an important role in these developments, both
by improving existing components and by allowing the
introduction of innovative components to new systems.
28
• Automotive Applications of Powder Metallurgy,
Woodhead Publishing Ltd. By P. Ramakrishnan
• https://en.Wikipedia.org/wiki/
Powder_Metallurgy
• www.edurite.com

29
Thank Y
u
30