Case Studies
1. Using powder metallurgy (PM/MIM) magnetic materials to save money in electromechanical devices
A large OEM approached Powder Metal Technologies with a handful of part models in the concept stage (end use was electrification).
Traditionally, the OEM would either stamp or CNC / Screw machine the parts, three methods their engineers were very familiar with.
However, before firming up the design, they chose to evaluate powder metallurgy paths to see if performance advantages and / or cost reduction was possible.
After a PMT customer on site review of all the parts, three candidate parts were selected for evaluation in both PM and MIM. Budgetary quotes and initial technical evaluations took place in only a few days. It was determined that one of the three parts would make a good PM part while the other two were good MIM candidates. Then, end use (application), material options, DFM were considered in multiple engineering TEAMS meetings with PMT suppliers. Best path to prototype transpired, testing multiple materials at the customer site for performance.
Testing results were assessed, final part designs and materials were agreed up.
All three parts resulted in a cost saving and equal or elevated performance for the OEM, who wisely incorporated powder metallurgy for a competitive advantage.
2. Bonding metal substrates using SPS to drastically reduce cycle time
SPS (Spark Plasma Sintering) is well known for its wide range of engineered material capabilities (such as technical ceramics, FGM’s and HEA’s). There is an added feature of SPS or FAST Sintering (Field Assisted Sintering).
It is the ability to bond or join by creating a liquid phase between dissimilar materials. The liquid phase is a localized overheating where the melting point is reached on the perimeter of the substrate (no brazing, soldering or adhesives).
This SPS bonding feature shortens cycle dramatically (up to 20 to 1) from conventional bonding methods.
First, the customer received a SPS ballpark bonding price (per stack). The quoted price was based on SPS cycle time and press loading (via a large, production style SPS press). Then the dissimilar material “stack” test runs took place at an R&D facility. Finally, bond strength and performance testing. After a handful of trials, bond strength met application requirements.
Spark Plasma Sintering has dynamic potential! For engineered materials and/or bonding, it makes sense to gut check SPS before defaulting to traditional methodologies, you might have a fit.
3.Reduce Neodymium magnet size by 1/3 to save money on raw material cost while meeting performance requirements
thAs permanent magnets become a fixture in new designs for electrification, there can be an over engineered approach to guarantee performance. Typically, this results in heavier magnets than needed.
The end result of this approach are magnets that use excessive raw material, and in the world of Neodymium, this means exponentially increased cost.
A customer new to permanent magnets emailed a drawing “over the wall” to Powder Metal Technologies (with a desired target price). Powder Metal Technologies placed the component and grade of Neodymium in front of their magnet supplier.
A handful of high-level engineering meetings were engaged in which the technical / application expertise of the supplier was self-evident. The end result? A quote that outlined options of magnet size & material grade as it related to performance.
Highlighting the quotation was a proposal that used 1/3 less material and nevertheless met performance requirements.
It really makes sense to work with experts on quality critical parts!
4. Use press and sinter high strength materials to replace expensive to machine 4140’s, 8620’s and forgings
By working closely with their metal powder suppliers, the press sinter and MIM suppliers represented by Powder Metal Technologies have developed specialty materials for use in extreme environments.
In MIM, the materials are high nickel grades such as Inconel 713C (excellent strength and corrosion resistance at high operating temperatures). In press and sinter, there is a focus on high strength materials (steel) such as chromium steels.
By substituting powder metal chromium steel for expensive to machine 4140’s, 8620’s and even forgings, OEMS can save real money. Recently, powder metal technology reviewed a 4140-steel component used in an industrial, quality critical application.
The budgetary quote showed a cost savings of over 50% (from the machine version). This savings justified a prototype and test program to qualify the chromium steel powder metal part.
Yes, some design changes were required, but powder metal technologies spear headed the effort with the supplier and OEM.
So far, this complex powder metal part has shipped over 500,000 pcs. and has a field performance history over 5 years, with no performance failures.
5.Technology transfer from machining to MIM / PM to save money
MIM. A large OEM had begun initial production of a new device. In the device was a small assembly. The small assembly consisted of two very small machined parts welded together. The very small parts were similar in shape and size but some geometric features were not identical, such as holes and steps. These two machined parts were welded together, then three very small pins inserted into the assembly. The MIM engineers creatively applied the MIM process (injection molded metal) to meet the customers challenge of a one piece solution. The end product was a single piece MIM design. The single piece combined the two half’s and the pins. It follows that the welding process and the pin insertion step were eliminated from the final product assembly. An elegant application of Metal Injection Molding (MIM).
PM, Press and Sinter. A plastic part was not performing in a sensor application. The OEM went right over a PM / MIM solution all the way to CNC machining. At a customer visit, the “problem part” (very expensive) was shown to Powder Metal Technologies. After some back and forth with the customer’s engineers, evaluating MIM, PM and working in partnership with PMT’s suppliers, it was determined that a clever press and sinter (PM) tooling solution would provide the least expensive price. While it is a small, inexpensive part, tight processing controls were critical to production and the quality teams worked hard, together, to ensure a robust process. This solution was a cost saving ultimately approved by the end customer quality team.
