Powder Metallurgy Design Excellence Award winners shine light on metal powder industry

August 2, 2022

The winners of the 2022 Powder Metallurgy Design Excellence Awards competition showcase outstanding examples of PM components (Courtesy MPIF)
The winners of the 2022 Powder Metallurgy Design Excellence Awards competition showcase outstanding examples of PM components (Courtesy MPIF)

The winners in the 2022 Powder Metallurgy Design Excellence Awards competition, sponsored by the Metal Powder Industries Federation (MPIF), were announced during the International Conference on Powder Metallurgy and Particulate Materials (PowderMet2022), held in Portland, Oregon, USA, from June 12–15, 2022.

This year’s winners are said to showcase outstanding examples of PM’s unique ability to challenge competing technologies, stated the MPIF. From lightweighting to complex geometries, Powder Metallurgy provides component designers with the ability to utilise advanced engineering methods that add up to part-to-part uniformity for improved product quality, shape and material flexibility, application versatility, and more.

In the design competition, a total of nine Grand Prizes and eighteen Awards of Distinction were presented across the manufacturing categories of conventional Powder Metallurgy (PM), Metal Injection Moulding (MIM) and metal Additive Manufacturing.

Here, we highlight the Powder Metallurgy winners.

Grand Prizes

Automotive – Engine category PM

This aluminium metal-matrix- composite outer gerotor is made by GKN Sinter Metals for its customer Pierburg (Courtesy MPIF)
This aluminium metal-matrix- composite outer gerotor is made by GKN Sinter Metals for its customer Pierburg (Courtesy MPIF)

A Grand Prize in the Automotive – Engine category for conventional PM components was awarded to GKN Sinter Metals and its customer Pierburg, for an aluminium metal-matrix- composite outer gerotor for an Italian luxury sports car dry sump pump. It is reputedly the first aluminium gerotor used in a dual-material aluminium-steel pump gear for a production vehicle application.

The inner profile of the gerotor for this high-performance application was critical for it to function in conjunction with a steel inner rotor with a different thermal expansion coefficient. The part provides a 50% reduction in rotating mass, which becomes even more significant with six gerotors per gang pump assembly.

MIM and metal AM

Further Grand Prize winners included parts made by MIM from Kyerim Metal Co., Ltd; ARC Group Worldwide and INDO-MIM Pvt Ltd, along with components produced by metal AM from Divergent Technologies, Inc, and 3DEO Inc.

Awards of Distinction

Automotive – Engine category PM

Nichols Portland was awarded for producing this eccentric ring used in a variable displacement oil pump (Courtesy MPIF)
Nichols Portland was awarded for producing this eccentric ring used in a variable displacement oil pump (Courtesy MPIF)

In the Automotive – Engine category for conventional PM components, an Award of Distinction was given to Nichols Portland LLC, a division of Nichols Portland Inc., for an eccentric ring used in a variable displacement oil pump. The sinter-hardened parts provide enhanced performance compared with prior generation designs that used steam-treated as-sintered parts.

DSB Technologies produced this 309L stainless steel sensor boss that is welded to an automotive exhaust system (Courtesy MPIF)
DSB Technologies produced this 309L stainless steel sensor boss that is welded to an automotive exhaust system (Courtesy MPIF)

In the same category, an Award of Distinction was also presented to DSB Technologies, LLC, formerly SSI Sintered Specialties LLC, and its customer Purem by Eberspaecher, for a 309L stainless steel sensor boss that is welded to an automotive exhaust system and holds a sensor for monitoring engine performance.

Automotive – Transmission category PM

The drive and driven sprockets, pressure plate and a sector gear are made for BorgWarner by Burgess-Norton Mfg. Co (Courtesy MPIF)
The drive and driven sprockets, pressure plate and a sector gear are made for BorgWarner by Burgess-Norton Mfg. Co (Courtesy MPIF)

In the Automotive – Transmission category for conventional PM components, an Award of Distinction was given to Burgess-Norton Mfg. Co., for drive & driven sprockets, a pressure plate, and a sector gear, made for BorgWarner, and used in an automotive transfer case. The sprockets are warm-die compacted from FL-4405 with admixed nickel.

Automotive – Chassis category PM

Metalpo Ind. Com Ltda received an award for this rack used in a braking system for trucks (Courtesy MPIF)
Metalpo Ind. Com Ltda received an award for this rack used in a braking system for trucks (Courtesy MPIF)

In the Automotive – Chassis category for conventional PM components, an Award of Distinction was presented to Metalpo Ind. Com Ltda and its customer Haldex do Brasil Ind e com Ltda, for a rack used in a braking system for trucks. The rack is made from diffusion-alloyed FD-0405, warm-die compacted and case hardened to achieve good wear properties.

Lawn & Garden/Off-Highway PM

Alpha Precision Group produced this camshaft assembly used in a family of engines ranging from 19–27 hp (Courtesy MPIF)
Alpha Precision Group produced this camshaft assembly used in a family of engines ranging from 19–27 hp (Courtesy MPIF)

In the Lawn & Garden/Off-Highway conventional PM components category, an Award of Distinction was given to Alpha Precision Group, a division of Nichols Portland Inc., for a camshaft assembly used in a family of engines ranging from 19–27 hp for consumer lawn and garden machines. The assembly comprises six PM components (a cam gear, four cam lobes, and a thrust washer). All five parts are assembled to the precision ground shaft by means of highly automated, specialised assembly cells.

This spider dampener insert, made by FMS Corporation, is part of a torque spider sub-assembly for ATV transmissions (Courtesy MPIF)
This spider dampener insert, made by FMS Corporation, is part of a torque spider sub-assembly for ATV transmissions (Courtesy MPIF)

This category also included a winning entry from FMS Corporation and their customer TEAM Industries for a spider dampener insert, part of a torque spider sub-assembly for ATV transmissions. The part was originally designed as a metal casting that required secondary machining, but was re-designed for PM in order to eliminate the need for extensive machining operations.

Hand Tools/Recreation PM

 Porite Taiwan produce this ring gear used in the gearbox of a cordless drill (Courtesy MPIF)
Porite Taiwan produce this ring gear used in the gearbox of a cordless drill (Courtesy MPIF)

In the Hand Tools/Recreation category for conventional PM components, an Award of Distinction was given to Porite Taiwan Co., Ltd., for a ring gear, used in the gearbox of a cordless drill. It is divided into two parts due to the multi-section appearance. The two PM parts are machined, pressed for alignment, followed by a plastic injection overmould operation.

Industrial Motors/Controls & Hydraulics PM

Nichols Portland received an award for this pump head sub-assembly used for fluid delivery (Courtesy MPIF)
Nichols Portland received an award for this pump head sub-assembly used for fluid delivery (Courtesy MPIF)

In the Industrial Motors/Controls & Hydraulics category for conventional PM components, an Award of Distinction was presented to Nichols Portland LLC, a division of Nichols Portland Inc., for a pump head sub-assembly for fluid delivery. The assembly comprises six PM parts, an inlet plate, eccentric ring, inner and outer gerotors, a spline coupling, and an outlet plate.

MIM and metal AM

Further Awards of Distinction included MIM parts from INDO-MIM Pvt Ltd., OptiMIM (a Form Technologies Company), Advanced Powder Products Inc., ARC Group Worldwide and PTI (Polymer Technologies Inc.). Metal additively manufactured component winners included Azoth and Amaero.

www.mpif.org

The winners of the 2022 Powder Metallurgy Design Excellence Awards competition showcase outstanding examples of PM components (Courtesy MPIF)

In the latest issue of PM Review…

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Extensive Powder Metallurgy industry news coverage, and the following exclusive deep-dive articles and reports:

  • Powder Metallurgy’s challenge: How does automotive’s reliance on model-based decision making impact our industry?
  • How to make metal powders. Part 4: Centrifugal and other special atomisation methods
  • Precision and energy efficiency in PM press technology: Insights from Ceramitec 2022
  • Historic traditions and new innovations: refractory metals and hard materials at the 20th Plansee Seminar
  • Tailoring a speciality alloy for Additive Manufacturing: From powder production to parameter optimisation
  • Understanding the compaction and sintering effects of four commonly used lubricants in Powder Metallurgy

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