Powder Metallurgy: Technologies and Global Markets

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Powder Metallurgy: Technologies and Global Markets

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INTRODUCTION

STUDY GOAL AND OBJECTIVES

This report, an update of an earlier BCC Research report, has the goal of providing the most up-to-date information on the current status of the global powder metallurgy market and to assess its growth potential during the period from 2012 to 2017. The different types of metal powders and their consumption in different applications are of particular interest.

REASONS FOR DOING THE STUDY

Powder metallurgy (PM) has been a steady industry over the past several decades, growing from the 1980s. Much of its growth derived from metal powder-based parts used to replace castings, forgings and machined parts. The industry has consistently demonstrated that it could meet the demand of manufacturers at a lower cost than other technologies.

PM technology is still evolving, and the industry has adopted particulates (i.e., powders and materials not made solely of metals). Products are changing too, and PM can be adapted or modified to meet their demands. BCC Research last examined this market in September 2010, and thus considers this an appropriate time to analyze recent developments.

SCOPE OF REPORT

This report analyzes the PM industry on a global basis, including manufacturing capability and consumption by regional markets. It also examines industry standards, government and industry support, and other key factors related to the success of powder metallurgy.

Market drivers within the industry are identified. The quantity and value of various powders and parts shipments is projected from 2011 to 2012, and then over a five-year period from 2012 to 2017. Technological issues and trends are projected and other influential factors are discussed.

The report identifies major manufacturers of powder metal and other related materials, such as ceramics and nanopowders, special alloys and metal matrix composites. It also includes companies that make parts and components for automotive products, industrial and tolling equipment, recreation and hobby items, appliances, business machines and other products.

METHODOLOGY

Both primary and secondary research methodologies were used in the preparation of this study. BCC Research presents an analysis of the volume shipped in 2011 for each major segment of the PM industry. The estimated value of shipments is based on the price the manufacturers paid in non-depreciated U.S. dollars.

Based on its analysis of PM properties, advantages, demand factors, competition and other information, BCC projects the potential growth in volume of each segment and forecasts price trends for 2012 and 2017 as the basis for estimating the value of shipments for these same time periods

INFORMATION SOURCES

BCC Research interviewed approximately 125 companies to obtain data for this study. Among the persons interviewed were chemists, process equipment specialists, marketing executives, operations personnel and users of various powder metal parts. Participants included representatives of the automotive industry, tooling companies and industrial buyers. Additional data were obtained from government publications, trade associations, industry and financial sources, and an exhaustive review of technical literature.

ANALYST'S CREDENTIALS

The author of the BCC report on which this updated edition is based is Robert H. Moran. Mr. Moran has worked as a technology market analyst and technology writer for more than 20 years and is the author of numerous BCC Research reports. He has authored reports covering various deposition technologies, displays, solar energy and solid-state lighting. He earned a B.S. degree in Economics from the University of Pennsylvania.

The analyst responsible for updating the report is Andrew McWilliams, a partner in the Boston–based international technology and marketing consulting firm 43rd Parallel LLC. Mr. McWilliams is the author or co-author of many other BCC studies, including studies in related fields such as AVM078A New Electronic Materials and Device Technologies: Global Markets; EGY053C Advanced Materials and Devices for Renewable Energy: Global Markets; AVM015F High-Performance Ceramic Coatings: Markets and Technologies; NAN015F Advanced Ceramics and Nanoceramic Powders; AVM028E Global Markets for Friction Products and Materials; and NAN021E Global Markets for Nanocomposites, Nanoparticles, Nanoclays and Nanotubes.

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION 1

STUDY GOAL AND OBJECTIVES 1

REASONS FOR DOING THE STUDY 1

SCOPE OF REPORT 1

METHODOLOGY 1

INFORMATION SOURCES 2

ANALYST'S CREDENTIALS 2

RELATED BCC REPORTS 2

BCC ONLINE SERVICES 2

DISCLAIMER 3

CHAPTER 2 SUMMARY 5

SUMMARY TABLE GLOBAL POWDER METALLURGY PARTS AND POWDER SHIPMENTS,

THROUGH 2017 (MILLION POUNDS/$ MILLIONS) 5

SUMMARY FIGURE GLOBAL POWDER METALLURGY PARTS AND POWDERS SHIPMENTS,

2011-2017 ($ MILLIONS) 6

CHAPTER 3 OVERVIEW 8

HISTORY 8

RECENT POWDER METALLURGY INDUSTRY ACTIVITY 9

POWDER METALLURGY PROCESS 9

TABLE 1 OVERVIEW OF THE POWDER METALLURGY PROCESS 9

MAKING METAL POWDERS 10

TABLE 2 BASIC POWDER MANUFACTURING PROCESSES 10

PARTICULATE MATERIALS 10

POWDER METALLURGY APPLICATIONS 10

TABLE 3 END PRODUCTS THAT USE POWDER METALLURGY PARTS 11

CHAPTER 4 INDUSTRY STRUCTURE 13

INDUSTRY STRUCTURE 13

TABLE 4 GLOBAL POWDER METALLURGY INDUSTRY STRUCTURE, 2011 14

KEY COMPANIES IN THE POWDER METALLURGY INDUSTRY 14

TABLE 5 KEY COMPANIES IN THE GLOBAL POWDER METALLURGY INDUSTRY 15

CHARACTERISTICS OF THE 2011 POWDER METALLURGY INDUSTRY 18

POWDER METALLURGY MANUFACTURING BY REGION 19

TABLE 6 GLOBAL SHARE OF POWDER METALLURGY MANUFACTURING BY REGION,

2011–2017 (%) 19

FIGURE 1 GLOBAL SHARE OF POWDER METALLURGY MANUFACTURING BY REGION,

2011–2017 (%) 19

CONSUMPTION OF POWDER METALLURGY PRODUCTS BY REGION 20

TABLE 7 POWDER METALLURGY CONSUMPTION BY REGION, 2011–2017 (%) 20

FIGURE 2 POWDER METALLURGY CONSUMPTION BY REGION, 2011–-2017 (%) 20

MARKET LEADERS 21

LEADING PARTS AND COMPONENT FABRICATORS 21

FIGURE 3 LEADING POWDER METALLURGY COMPONENT MANUFACTURERS, 2011 (%) 22

LEADING METAL POWDER PRODUCERS 23

FIGURE 4 LEADING POWDER METALLURGY POWDER MANUFACTURERS, 2011 (%) 23

COMPANY PROFILES 24

ACUPOWDER INTERNATIONAL 24

ADVANCED MATERIALS TECHNOLOGIES PTE LTD. 24

ADVANCED METALWORKING PRACTICES 25

ALPHA SINTERED METAL INC. 25

BASF 26

BORGWARNER INC. 27

CAPSTAN 27

CARPENTER TECHNOLOGY CORPORATION 28

CHICAGO POWDER METAL PRODUCTS 29

DORST TECHNOLOGIES 30

FEDERAL-MOGUL CORP 30

FUKUDA METAL FOIL AND POWDER CO. LTD. 31

GKN SINTER METALS 32

H.C. STARCK 32

HITACHI POWDERED METALS CO. LTD. 33

HOEGANAES CORPORATION 34

HOGANAS AB 34

KENNAMETAL INC. 35

METAL POWDER PRODUCTS COMPANY 36

MIBA AG 36

NIPPON KAGAKU YAKIN COMPANY LTD. 37

NIPPON PISTON RING CO. LTD. 38

OBE GMBH 38

RAINBOW MING INDUSTRIAL CO. 39

STACKPOLE LIMITED 39

CHAPTER 5 TECHNOLOGY 42

CONVENTIONAL POWDER METALLURGY 42

TABLE 8 POWDER METALLURGY PROCESS 43

POWDER MIXING 43

COMPACTING 44

Single-Action Pressing 44

Multiaction Pressing 44

Double-Die Pressing 45

TABLE 9 PARTS BY COMPLEXITY, THICKNESS AND PRESSING 45

SINTERING 45

TABLE 10 CONTINUOUS-SINTERING FURNACES BY TYPE 45

Sinter Hardening 46

FULLY DENSE PROCESSING 46

HOT ISOSTATIC PRESSING 47

TABLE 11 BASIC HOT ISOSTATIC PRESSING PROCESS 47

COLD ISOSTATIC PRESSING 48

TABLE 12 BASIC COLD ISOSTATIC PRESSING PROCESS 48

ROLL COMPACTION 48

HOT EXTRUSION 49

METAL-INJECTION MOLDING 49

TABLE 13 BASIC METAL INJECTION MOLDING PROCESS 49

Powder-Injection Molding 50

HIGH-DENSITY PROCESSING OF FERROUS METAL PARTS 50

IMPACT OF RAW MATERIALS 50

DIE WALL LUBRICATION 51

HIGH-TEMPERATURE SINTERING 51

WARM COMPACTION 51

TABLE 14 WARM COMPACTING PROCESS 52

POWDER FORGING 52

SECONDARY OPERATIONS 53

TABLE 15 SECONDARY OPERATIONS 53

COINING AND SIZING 54

IMPREGNATION 54

INFILTRATION 54

HEAT TREATING 54

MACHINING 55

FINISHING 55

METAL POWDER PRODUCTION AND PROCESSING 55

FERROUS-POWDER PRODUCTION 55

Atomization 55

TABLE 16 WATER AND GAS ATOMIZATION PROCESS COMPARISONS 56

Reduction of Oxides 56

Electrolytic Deposition 57

OTHER POWDER PROCESSING OPERATIONS 57

Diffusion Bonding 57

Segregation-Free Processing 57

NONFERROUS POWDER PRODUCTION 57

Aluminum-Based Powders 57

Air or Inert Gas Atomization 57

Ball Milling 58

Copper-Based Powders 58

Oxide Reduction 58

Water or Air Atomization 58

Nickel-Based Powders 58

Hydrometallurgical Processing 58

Gas Atomization 58

Plasma-Rotating Electrode Process 58

Titanium-Based Powders 59

Kroll Process 59

Plasma Quench Processing 59

Refractory Metal Powders 59

RECENT DEVELOPMENTS 59

EXPANDING THE DEFINITION OF POWDER METALLURGY MATERIALS 60

TABLE 17 PARTICULATE MATERIALS 60

IMPACT OF PARTICULATES ON INDUSTRY EXPANSION 60

Materials Mix 60

Benefits to the Industry 60

TABLE 18 BENEFITS OF ADDED MATERIALS TO THE POWDER METALLURGY INDUSTRY 60

Make or Outsource Materials 61

Component Manufacture Modifications 62

ADVANCES IN MATERIALS AND PRODUCTION TECHNOLOGY 62

Other Injection-Molding Processes 62

ADVANCED CERAMIC POWDERS 62

Powder Types 63

TABLE 19 COMMONLY USED ADVANCED CERAMIC MATERIALS 63

Powder-Synthesis Techniques 64

NANO-CERAMIC POWDERS 64

Nanocomposite Ceramic Powder 64

Nanoceramic Applications 65

TABLE 20 COMMERCIAL APPLICATIONS FOR CERAMIC NANOPOWDERS 65

CONCLUSION 65

PATENT ANALYSIS 65

PATENTS BY SUBJECT MATTER 66

TABLE 21 PATENTS BY AREA OF POWDER METALLURGY TECHNOLOGY, 2008–AUGUST 2012 66

PATENTS BY REGION 67

TABLE 22 POWDER METALLURGY PATENTS BY REGION, 2008–AUGUST 2012 67

PATENTS BY COMPANIES 67

TABLE 23 COMPANIES WITH TWO OR MORE PATENTS, 2008-AUGUST 2012 68

SAMPLE ABSTRACTS 69

Method of Using a Feedstock Composition for Powder Metallurgy 69

Powder Metallurgical Compositions Containing Organometallic Lubricants 69

Powder Metallurgy Sputtering Targets and Their Production Methods 69

Making Sinter-Forged, High-Strength Aluminum Parts 70

Method for Making a Forged, Carburized Powder-Metal Part 70

Making a Turbine Blisk 70

CHAPTER 6 COMPETITIVE ENVIRONMENT 72

ECONOMIC TRENDS 72

FIGURE 5 ANNUAL GROWTH RATE OF GLOBAL GROSS DOMESTIC PRODUCT, 2010-2017

(AAGR%) 72

MOTOR VEHICLE PRODUCTION 73

TABLE 24 GLOBAL MOTOR VEHICLE PRODUCTION, THROUGH 2017 (MILLION UNITS) 73

INDUSTRY AND TRADE SUPPORT 73

NORTH AMERICA 73

Metal Powder Industries Federation 73

TABLE 25 TRADE ASSOCIATIONS IN THE METAL POWDER INDUSTRIES FEDERATION 74

Pennsylvania State University Center for Innovative Sintered Products 74

TABLE 26 PENNSYLVANIA STATE UNIVERSITY CENTER FOR INNOVATIVE SINTERED

PRODUCTS COLLABORATIVE UNIVERSITIES 75

EUROPE 75

European Powder Metallurgy Association 75

TABLE 27 EUROPEAN POWDER METALLURGY ASSOCIATION'S KEY GOALS 76

ASIA-PACIFIC 76

Japan Powder Metallurgy Association 76

Powder Metallurgy Association of India 77

TABLE 28 POWDER METALLURGY ASSOCIATION OF INDIA'S MAJOR OBJECTIVES 77

OTHER REGIONS 77

STANDARDS DEVELOPMENT 78

TEST METHODS 78

POWDER-PRESS SAFETY STANDARDS 78

OTHER STANDARDS 78

CHAPTER 7 POWDER METALLURGY MATERIALS AND PARTS MARKETS 80

FERROUS POWDER METALS AND PARTS 80

FERROUS METAL-POWDER CHARACTERISTICS AND PROPERTIES 80

Metal-Powder Properties 80

Particle Size and Distribution 80

TABLE 29 STANDARD U.S. SIEVE SIZES 81

Apparent or Tap Density 81

Flow Rate 81

TABLE 30 SAMPLE PHYSICAL CHARACTERISTICS OF COMMERCIAL IRON-BASED POWDERS 82

Ferrous-Powder Types 82

TABLE 31 SAMPLE COMPOSITION OF SINTERED AUTOMOTIVE STEEL STRUCTURAL

COMPONENT MATERIALS 82

FERROUS POWDER METALLURGY APPLICATIONS 83

Automotive Applications 83

TABLE 32 REPRESENTATIVE AUTOMOTIVE APPLICATIONS FOR POWDER METALLURGY

PARTS 83

Ferrous Structural Automotive Parts 83

Engine Connecting Rods 84

Engine Main-Bearing Caps 84

Camshaft Lobes 85

Exhaust-System Flanges 85

Bearings, Gears and Sprockets 85

Transmission Components 86

Torque Converter Turbine Hubs 86

Valve Guides and Valve Seat Inserts 87

Steering Systems 87

Braking Systems 87

Ferrous Self-Lubricating Bearings 87

Ferrous Magnetic Parts 88

Ferrous Friction Materials 88

Advantages of Powder Metallurgies in Automotive Applications 89

TABLE 33 ADVANTAGES OF POWDER METALLURGIES IN AUTOMOTIVE APPLICATIONS 89

Non-Automotive Applications of Ferrous-Powder Metallurgies 89

MARKET ANALYSIS 90

Iron and Steel Powders 90

TABLE 34 GLOBAL SHIPMENTS OF IRON AND STEEL POWDERS AND PARTS, THROUGH 2017

(MILLION POUNDS/$ MILLIONS) 90

FIGURE 6 GLOBAL IRON AND STEEL POWDERS AND PARTS SHIPMENTS, 2011–2017 ($

MILLIONS) 90

Volume Projections 91

TABLE 35 GLOBAL SHIPMENT TRENDS FOR MOTOR VEHICLES AND IRON AND STEEL

POWDERS, 2007–2011 (MILLION VEHICLES/MILLION TONS) 91

Price Considerations 92

STAINLESS-STEEL POWDERS 92

Characteristics and Properties 92

Applications 92

TABLE 36 MAJOR APPLICATIONS FOR STAINLESS-STEEL POWDERS 92

Market Analysis 93

TABLE 37 GLOBAL SHIPMENTS OF STAINLESS-STEEL POWDERS AND PARTS, THROUGH

2017 (MILLION POUNDS/$ MILLIONS) 94

FIGURE 7 GLOBAL SHIPMENTS OF STAINLESS-STEEL POWDERS AND PARTS, 2011–2017 ($

MILLIONS) 94

ALUMINUM POWDERS AND PARTS 94

ALUMINUM POWDER AND PARTS PROPERTIES 95

Advantages of Aluminum Powder Metallurgy 95

TABLE 38 ADVANTAGES OF ALUMINUM POWDER METALLURGY 95

Search for Weight Reduction 95

Density: A Positive Factor 96

ALUMINUM POWDER APPLICATIONS 96

Automotive Applications 96

Cam-Shaft Bearing Caps 96

Aerospace Applications 97

Metal Matrix Composites 97

TABLE 39 METAL MATRIX COMPOSITE MANUFACTURING METHODS 97

Thermal Management Applications 98

Other Applications 98

ALUMINUM POWDER AND PARTS MARKET ASSESSMENT 98

TABLE 40 GLOBAL SHIPMENTS OF ALUMINUM POWDER AND PARTS, THROUGH 2017

(MILLION POUNDS/$ MILLIONS) 99

FIGURE 8 GLOBAL SHIPMENTS OF ALUMINUM POWDERS AND PARTS, 2011–2017 ($

MILLIONS) 99

Volume Projections 99

Price Considerations 100

COPPER POWDERS AND COPPER-BASED PARTS 100

COPPER POWDER PROPERTIES 100

TABLE 41 PRIMARY ADVANTAGES OF COPPER POWDER 101

COPPER POWDER METALLURGY APPLICATIONS 101

Hybrid Vehicles 101

Bronze Bearings, Filters and Related Parts 101

High-Conductivity Structural Parts 102

Other Copper Powder Metallurgy Applications 102

Friction Materials 102

COPPER POWDER AND PARTS MARKET ASSESSMENT 102

TABLE 42 GLOBAL COPPER POWDER AND PARTS SHIPMENTS, THROUGH 2017 (MILLION

POUNDS/$ MILLION) 103

FIGURE 9 GLOBAL COPPER POWDERS AND PARTS SHIPMENTS, 2011–2017 ($ MILLIONS) 103

Volume Projections 104

Price Considerations 104

NICKEL-BASED POWDERS AND PARTS 104

NICKEL-POWDER PROPERTIES 104

TABLE 43 NICKEL-POWDER PROPERTIES 105

NICKEL-POWDER APPLICATIONS 105

TABLE 44 NICKEL-POWDER APPLICATIONS BY POWDER TYPE 106

NICKEL POWDER AND PARTS MARKET ASSESSMENT 106

TABLE 45 GLOBAL NICKEL POWDER AND PART SHIPMENTS, THROUGH 2017 (MILLION

POUNDS/$ MILLIONS) 107

FIGURE 10 GLOBAL NICKEL POWDER AND PART SHIPMENTS, 2011–2017 ($ MILLIONS) 107

Volume Projections 107

Price Considerations 108

MARKETS FOR TUNGSTEN AND MOLYBDENUM POWDERS AND ALLOY PM PARTS 108

PROPERTIES 108

Tungsten 108

Molybdenum 108

APPLICATIONS 108

Tungsten 108

Molybdenum 109

TUNGSTEN AND MOLYBDENUM POWDER AND PARTS MARKET ASSESSMENT 110

TABLE 46 GLOBAL TUNGSTEN AND MOLYBDENUM-POWDER AND PARTS SHIPMENTS,

THROUGH 2017 (MILLION POUNDS/$ MILLIONS) 110

FIGURE 11 GLOBAL TUNGSTEN AND MOLYBDENUM POWDER AND PARTS SHIPMENTS,

2011–2017 ($ MILLIONS) 111

Volume Projections 111

Price Considerations 111

TIN POWDERS AND TIN-BASE PARTS 112

PROPERTIES 112

APPLICATIONS 112

TABLE 47 MAJOR TIN POWDER APPLICATIONS 112

TIN POWDER AND PARTS MARKET ASSESSMENT 113

TABLE 48 GLOBAL TIN POWDER AND PARTS SHIPMENTS, THROUGH 2017 (MILLION

POUNDS/$ MILLION) 113

FIGURE 12 GLOBAL SHIPMENTS OF TIN POWDERS AND PARTS, 2011–2017 ($ MILLIONS) 114

Volume Projections 114

Price Considerations 114

PARTICULATES AND OTHER ADVANCED MATERIALS 114

PROPERTIES 115

Special Alloy Materials 115

TABLE 49 ALLOYS WITH HIGH-CARBON CONTENT (%) 115

Ceramic Powders 115

Nanoceramic Powders 116

TABLE 50 METHODS FOR MAKING NANOPOWDERS 116

APPLICATIONS 117

TABLE 51 PARTICULATE AND OTHER ADVANCED-MATERIAL APPLICATIONS 117

PARTICULATE AND OTHER ADANCED-MATERIAL MARKET ASSESSMENT 118

TABLE 52 GLOBAL PARTICULATE AND OTHER ADVANCED POWDER AND PARTS SHIPMENTS,

THROUGH 2017 (MILLION POUNDS/$ MILLIONS) 118

FIGURE 13 GLOBAL PARTICULATE AND OTHER ADVANCED POWDER AND PARTS

SHIPMENTS, 2011–2017 ($ MILLIONS) 118

Volume Projections 119

FIGURE 14 PARTICULATES AND SPECIAL POWDERS MARKET SHARES, 2011 (%) 119

Pricing Considerations 120

GLOBAL POWDER AND PARTS GROWTH 120

POWDER METALLURGY MATERIALS 120

Volume 120

TABLE 53 GLOBAL POWDER METAL SHIPMENT VOLUME AND MARKET SHARE BY

MATERIAL TYPE, THROUGH 2017 (SHORT TONS/% MARKET SHARE) 121

FIGURE 15 GLOBAL SHIPMENT VOLUME OF POWDER MATERIALS BY MATERIAL TYPE,

2011–2017 (SHORT TONS) 122

FIGURE 16 GLOBAL POWDER METAL SHIPMENTS BY MATERIAL TYPE, 2011–2017 (%) 123

Value 123

TABLE 54 GLOBAL POWDER METALLURGY MARKET BY MATERIAL TYPE, THROUGH 2017 ($

MILLION AND % MARKET SHARE) 123

FIGURE 17 GLOBAL POWDER METALLURGY SHIPMENTS BY MATERIAL TYPE, 2011–2017 ($

MILLIONS) 124

FIGURE 18 GLOBAL POWDER METALLURGY SHIPMENTS BY MATERIAL TYPE, 2011–2017 (%) 124

PARTS 125

Parts Shipments by Powder Metal Type 125

TABLE 55 GLOBAL POWDER METALLURGY PARTS SHIPMENTS, 2011-2017 (MILLION

POUNDS/$ MILLIONS) 125

Parts Shipments by End Use Type 126

TABLE 56 GLOBAL POWDER METALLURGY COMPONENT SHIPMENTS AND SHARE BY

MARKET TYPE, THROUGH 2017 ($ MILLIONS/% MARKET SHARE) 126

FIGURE 19 GLOBAL POWDER METALLURGY COMPONENT SHIPMENTS BY MARKET TYPE,

2011–2017 ($ MILLIONS) 126

FIGURE 20 GLOBAL POWDER METALLURGY COMPONENT SHARE BY MARKET TYPE,

2011–2017 (%) 127

LIST OF TABLES

SUMMARY TABLE GLOBAL POWDER METALLURGY PARTS AND POWDER SHIPMENTS,

THROUGH 2017 (MILLION POUNDS/$ MILLIONS) 5

TABLE 1 OVERVIEW OF THE POWDER METALLURGY PROCESS 9

TABLE 2 BASIC POWDER MANUFACTURING PROCESSES 10

TABLE 3 END PRODUCTS THAT USE POWDER METALLURGY PARTS 11

TABLE 4 GLOBAL POWDER METALLURGY INDUSTRY STRUCTURE, 2011 14

TABLE 5 KEY COMPANIES IN THE GLOBAL POWDER METALLURGY INDUSTRY 15

TABLE 6 GLOBAL SHARE OF POWDER METALLURGY MANUFACTURING BY REGION,

2011–2017 (%) 19

TABLE 7 POWDER METALLURGY CONSUMPTION BY REGION, 2011–2017 (%) 20

TABLE 8 POWDER METALLURGY PROCESS 43

TABLE 9 PARTS BY COMPLEXITY, THICKNESS AND PRESSING 45

TABLE 10 CONTINUOUS-SINTERING FURNACES BY TYPE 45

TABLE 11 BASIC HOT ISOSTATIC PRESSING PROCESS 47

TABLE 12 BASIC COLD ISOSTATIC PRESSING PROCESS 48

TABLE 13 BASIC METAL INJECTION MOLDING PROCESS 49

TABLE 14 WARM COMPACTING PROCESS 52

TABLE 15 SECONDARY OPERATIONS 53

TABLE 16 WATER AND GAS ATOMIZATION PROCESS COMPARISONS 56

TABLE 17 PARTICULATE MATERIALS 60

TABLE 18 BENEFITS OF ADDED MATERIALS TO THE POWDER METALLURGY INDUSTRY 60

TABLE 19 COMMONLY USED ADVANCED CERAMIC MATERIALS 63

TABLE 20 COMMERCIAL APPLICATIONS FOR CERAMIC NANOPOWDERS 65

TABLE 21 PATENTS BY AREA OF POWDER METALLURGY TECHNOLOGY, 2008–AUGUST 2012 66

TABLE 22 POWDER METALLURGY PATENTS BY REGION, 2008–AUGUST 2012 67

TABLE 23 COMPANIES WITH TWO OR MORE PATENTS, 2008-AUGUST 2012 68

TABLE 24 GLOBAL MOTOR VEHICLE PRODUCTION, THROUGH 2017 (MILLION UNITS) 73

TABLE 25 TRADE ASSOCIATIONS IN THE METAL POWDER INDUSTRIES FEDERATION 74

TABLE 26 PENNSYLVANIA STATE UNIVERSITY CENTER FOR INNOVATIVE SINTERED

PRODUCTS COLLABORATIVE UNIVERSITIES 75

TABLE 27 EUROPEAN POWDER METALLURGY ASSOCIATION'S KEY GOALS 76

TABLE 28 POWDER METALLURGY ASSOCIATION OF INDIA'S MAJOR OBJECTIVES 77

TABLE 29 STANDARD U.S. SIEVE SIZES 81

TABLE 30 SAMPLE PHYSICAL CHARACTERISTICS OF COMMERCIAL IRON-BASED POWDERS 82

TABLE 31 SAMPLE COMPOSITION OF SINTERED AUTOMOTIVE STEEL STRUCTURAL

COMPONENT MATERIALS 82

TABLE 32 REPRESENTATIVE AUTOMOTIVE APPLICATIONS FOR POWDER METALLURGY

PARTS 83

TABLE 33 ADVANTAGES OF POWDER METALLURGIES IN AUTOMOTIVE APPLICATIONS 89

TABLE 34 GLOBAL SHIPMENTS OF IRON AND STEEL POWDERS AND PARTS, THROUGH 2017

(MILLION POUNDS/$ MILLIONS) 90

TABLE 35 GLOBAL SHIPMENT TRENDS FOR MOTOR VEHICLES AND IRON AND STEEL

POWDERS, 2007–2011 (MILLION VEHICLES/MILLION TONS) 91

TABLE 36 MAJOR APPLICATIONS FOR STAINLESS-STEEL POWDERS 92

TABLE 37 GLOBAL SHIPMENTS OF STAINLESS-STEEL POWDERS AND PARTS, THROUGH 2017

(MILLION POUNDS/$ MILLIONS) 94

TABLE 38 ADVANTAGES OF ALUMINUM POWDER METALLURGY 95

TABLE 39 METAL MATRIX COMPOSITE MANUFACTURING METHODS 97

TABLE 40 GLOBAL SHIPMENTS OF ALUMINUM POWDER AND PARTS, THROUGH 2017

(MILLION POUNDS/$ MILLIONS) 99

TABLE 41 PRIMARY ADVANTAGES OF COPPER POWDER 101

TABLE 42 GLOBAL COPPER POWDER AND PARTS SHIPMENTS, THROUGH 2017 (MILLION

POUNDS/$ MILLION) 103

TABLE 43 NICKEL-POWDER PROPERTIES 105

TABLE 44 NICKEL-POWDER APPLICATIONS BY POWDER TYPE 106

TABLE 45 GLOBAL NICKEL POWDER AND PART SHIPMENTS, THROUGH 2017 (MILLION

POUNDS/$ MILLIONS) 107

TABLE 46 GLOBAL TUNGSTEN AND MOLYBDENUM-POWDER AND PARTS SHIPMENTS,

THROUGH 2017 (MILLION POUNDS/$ MILLIONS) 110

TABLE 47 MAJOR TIN POWDER APPLICATIONS 112

TABLE 48 GLOBAL TIN POWDER AND PARTS SHIPMENTS, THROUGH 2017 (MILLION

POUNDS/$ MILLION) 113

TABLE 49 ALLOYS WITH HIGH-CARBON CONTENT (%) 115

TABLE 50 METHODS FOR MAKING NANOPOWDERS 116

TABLE 51 PARTICULATE AND OTHER ADVANCED-MATERIAL APPLICATIONS 117

TABLE 52 GLOBAL PARTICULATE AND OTHER ADVANCED POWDER AND PARTS SHIPMENTS,

THROUGH 2017 (MILLION POUNDS/$ MILLIONS) 118

TABLE 53 GLOBAL POWDER METAL SHIPMENT VOLUME AND MARKET SHARE BY MATERIAL

TYPE, THROUGH 2017 (SHORT TONS/% MARKET SHARE) 121

TABLE 54 GLOBAL POWDER METALLURGY MARKET BY MATERIAL TYPE, THROUGH 2017 ($

MILLION AND % MARKET SHARE) 123

TABLE 55 GLOBAL POWDER METALLURGY PARTS SHIPMENTS, 2011-2017 (MILLION

POUNDS/$ MILLIONS) 125

TABLE 56 GLOBAL POWDER METALLURGY COMPONENT SHIPMENTS AND SHARE BY

MARKET TYPE, THROUGH 2017 ($ MILLIONS/% MARKET SHARE) 126

LIST OF FIGURES

SUMMARY FIGURE GLOBAL POWDER METALLURGY PARTS AND POWDERS SHIPMENTS,

2011-2017 ($ MILLIONS) 6

FIGURE 1 GLOBAL SHARE OF POWDER METALLURGY MANUFACTURING BY REGION,

2011–2017 (%) 19

FIGURE 2 POWDER METALLURGY CONSUMPTION BY REGION, 2011–-2017 (%) 20

FIGURE 3 LEADING POWDER METALLURGY COMPONENT MANUFACTURERS, 2011 (%) 22

FIGURE 4 LEADING POWDER METALLURGY POWDER MANUFACTURERS, 2011 (%) 23

FIGURE 5 ANNUAL GROWTH RATE OF GLOBAL GROSS DOMESTIC PRODUCT, 2010-2017

(AAGR%) 72

FIGURE 6 GLOBAL IRON AND STEEL POWDERS AND PARTS SHIPMENTS, 2011–2017 ($

MILLIONS) 90

FIGURE 7 GLOBAL SHIPMENTS OF STAINLESS-STEEL POWDERS AND PARTS, 2011–2017 ($

MILLIONS) 94

FIGURE 8 GLOBAL SHIPMENTS OF ALUMINUM POWDERS AND PARTS, 2011–2017 ($

MILLIONS) 99

FIGURE 9 GLOBAL COPPER POWDERS AND PARTS SHIPMENTS, 2011–2017 ($ MILLIONS) 103

FIGURE 10 GLOBAL NICKEL POWDER AND PART SHIPMENTS, 2011–2017 ($ MILLIONS) 107

FIGURE 11 GLOBAL TUNGSTEN AND MOLYBDENUM POWDER AND PARTS SHIPMENTS,

2011–2017 ($ MILLIONS) 111

FIGURE 12 GLOBAL SHIPMENTS OF TIN POWDERS AND PARTS, 2011–2017 ($ MILLIONS) 114

FIGURE 13 GLOBAL PARTICULATE AND OTHER ADVANCED POWDER AND PARTS SHIPMENTS,

2011–2017 ($ MILLIONS) 118

FIGURE 14 PARTICULATES AND SPECIAL POWDERS MARKET SHARES, 2011 (%) 119

FIGURE 15 GLOBAL SHIPMENT VOLUME OF POWDER MATERIALS BY MATERIAL TYPE,

2011–2017 (SHORT TONS) 122

FIGURE 16 GLOBAL POWDER METAL SHIPMENTS BY MATERIAL TYPE, 2011–2017 (%) 123

FIGURE 17 GLOBAL POWDER METALLURGY SHIPMENTS BY MATERIAL TYPE, 2011–2017 ($

MILLIONS) 124

FIGURE 18 GLOBAL POWDER METALLURGY SHIPMENTS BY MATERIAL TYPE, 2011–2017 (%) 124

FIGURE 19 GLOBAL POWDER METALLURGY COMPONENT SHIPMENTS BY MARKET TYPE,

2011–2017 ($ MILLIONS) 126

FIGURE 20 GLOBAL POWDER METALLURGY COMPONENT SHARE BY MARKET TYPE,

2011–2017 (%) 127

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