David Whittaker

The competition for automotive connecting rod markets

Abstract Powder forged connecting rods for petrol engines are one of the great automotive success stories for powder metallurgy (PM) technology, stealing increasing market share from drop forged rods. However, the drop forging industry is now seeking to arrest this erosion, and the imminent introduction of series production single press/sinter connecting rods is a further threat to the position of the powder forged components. David Whittaker reviews developments in all three connecting-rod manufacturing processes, and assesses their strengths and cost-competitiveness.

PM structural parts move to higher density and performance

Abstract The automotive market is particularly important for PM (ferrous) structural parts. Growth in this market initially relied on developments in shape complexity and size of PM products, but, more recently, achieving higher performance has been identified as an important means of maintaining growth. Achieving higher density levels has also emerged as a prime means of increasing performance of PM structural parts. The industrys original attack on this objective, powder forging, is considered and the successes and limitations of the process defined. More recent process and/or material developments, that are closer variants on the basic press/sinter PM technology, are then described. These comprise three possible approaches: increasing green density; densification during sintering; and an additional post-sintering densification step, often applied locally rather than throughout the part. In each case, detailed developments are described and important product application types highlighted. Finally, the market penetration already secured into higher performance automotive applications is considered and a personal view provided on which issues might control the pace of future market penetration.

The PM structural parts industry — past growth and future prospects

As we stand on the brink of a new millennium, it is useful to remind ourselves how recently PM technology has appeared on the scene compared with many competitive processes. In this article, David Whittaker takes stock of past achievements and attempts to predict the future for PM structural components.

Future prospects for titanium powder metallurgy markets

This chapter begins by discussing the market sectors that have been penetrated to date by wrought and cast titanium products. Established applications for titanium powders are also briefly discussed. In relation to the interest in PM titanium, reported R&D activity is then separated into two broad application sector categories: (a) those that are already committed to (wrought or cast route) titanium and titanium alloys as a “material of choice” and are therefore fully aware of the high raw material costs involved and (b) those where titanium alloy products are not currently being specified, with the high costs involved being seen as the major impediment. Potential new PM titanium applications and consequent R&D activities in a range of application sectors that fall within the broad category (a) are then discussed, with particular reference to aero-engine, airframe, health care, and jewelry applications. Prospects in a number of application sectors in category (b) are then considered in the context of the raw material types and PM forming technologies that are being addressed in the reported R&D activity. Finally, some projections are attempted of potential market penetration in a 5-year time frame for PM titanium products of various types.

Powder processing, consolidation and metallurgy of titanium

The event, held on 5–7 December 2011, was co-sponsored by Materials Australia (MA), the Titanium Industry Development Association, New Zealand (TiDA), The Minerals, Metals & Materials Society (TMS), Japan Society of Powder and Powder Metallurgy (JSPM) and the Chinese Society for Metals (CSM), and was organised largely through the indefatigable efforts of Dr Ma Qian of the University of Queensland. The conference attracted 127 registrants from 15 countries for a packed three day programme comprising a total of 78 presentations and a panel discussion on issues critical to the future development of titanium PM.

Ferrous materials continue to expand

Abstract With ferrous powders now dominating powder metallurgy (PM) shipments it is easy to forget that this has not always been the case. Fifty years ago, the use of ferrous materials was still dwarfed by that of copper and bronze powders. A half century of advances in materials, equipments and product design, however, has well and truly reversed this position. David Whittaker and Arthur Rowley review the rise to prominence of ferrous PM.

End-user confidence key to confirm the PM success story

Although PM offers a wide range of materials and processes for the manufacture of higher density and high performance products, the important issue of end user confidence is key to determining the speed and depth of the technologys market penetration, says David Whittaker…

Ferrous PM structural parts in automotive applications — is further growth possible?

Abstract Powder metallurgy (PM) technology finds application for one or both of two reasons: It is a cost-effective method for manufacturing the particular part, compared with other potential process routes. It offers some aspect of ‘product uniqueness’, which cannot be generated readily, or even at all, by more conventional routes. Ferrous PM structural parts, in automotive component application, are almost always driven by the cost-effectiveness criterion. This article will therefore concentrate on this type of application.

Particulate materials for energy applications

Abstract A one-day workshop focusing on energy applications, organised by the Particulate Engineering Committee of the Institute of Materials, Minerals and Mining (IOM3) and co-sponsored by the Materials Knowledge Transfer Network (KTN), was held at the Riverside Centre, Derby on 15 May 2013.

EPMA drives collaborative development projects

EPMA has played a key role in initiating ground breaking collaborative projects involving industry, the research community and academia. Two examples are reviewed here: the PM-Modnet European thematic network and the Global PM Properties Database to promote PM via the provision of design data to end users. The following contribution by Georg Schlieper reviews the thematic network on European standards for metal injection moulding.