Metal Powders. A Global Survey of Production, Applications and Markets to 2010

226 Pages·5.816 MB·English

by  Joseph M Capus (Auth.)

List of Tables
Summary
Table 1 Estimated Global Markets for Metal Powders 2005
Summary Estimated Breakdown of Ferrous and Copper-base
Table 2 Powders for MP Fabrication and Other Applications
2004 (tonnes)
Summary Regional Markets for Ferrous and Copper-base
Table 3 Powders 2001-2010 (tonnes)
Table 1.1 Non-Ferrous Metal Powder Shipments in North
America 1990-1999 (tonnes) 31
Table 2.1 West European Shipments of Ferrous and
Copper-based Powders for MP 99--0991 (tonnes) 14
Table 3.1 Japanese Consumption of Ferrous and
Copper-based Powders 1990-1999 (tonnes) 15
Table 1.2 North American Metal Powder Shipments
1995-2003 (tonnes) 02
Table 2.2 Iron-based and Copper-based MP Part Production in
Japan 1998-2004 (tonnes) 26
Table 3.2 Breakdown of Japanese MP Production 1998-2004
(tonnes) 26
Table 2.4 Japanese Production of Non-Automotive MP
Structural Parts 1998-2004 (tonnes) 72
Table 5.2 Analysis of Japanese MP Bearings Production
1998-2004 (tonnes) 28
Table 6.2 Value of MP Products Manufactured in W Europe
8991 and 2001 E( million) 30
Table 7.2 Estimated Market Shares of W European Countries
in MP Parts Production 2002 03
Table 8.2 Production of MP Structural Parts, Bearings
and Filters in Germany 1997-2003 (tonnes) 34
Table 9.2 Production of Metal Powders and MP Parts in
Italy 1997-2002 (tonnes) 53
Table 2.10 Ferrous MP Parts Production in Russia and East
Europe (tonnes) 40
Table 11.2 MP Part Production in Asia and Australia,
ex-Japan 1998-2004 (tonnes) 14
Table 2.12 Breakdown of MP Part Production in Asia 2003 )%( 24
Table 2.13 Motor Vehicle Production in Asian Countries 2003
(thousands) 42
Metal Powders ix
List of selbaT
Table 2.14 MP Part Production and Applications in Australia
1998-2002 (tonnes) 34
Table 2.15 MP Parts Production in China 1998-2004 (tonnes) 44
Table 2.16 MP Parts Production in India 1998-2003 (tonnes) 74
Table 2.17 Car and Light Vehicle Production in Leading
Countries, from Various Sources (million) 25
Table 2.18 Development of PM Content in Cars, N America,
W Europe and Japan 1998-2004, kg/vehicle 45
Table 1.3 Summary of Global Markets for Ferrous and
Non-Ferrous Powders 2001-2010 (tonnes) 85
Table 2.3 Summary of Global Markets for Ferrous
and Non-Ferrous Powders by Approximate Value
(US$ million) 95
Table 3.3 North American Consumption of Iron and
Steel Powders 1990-2004 (thousands of tonnes) 26
Table 4.3 Estimates of Weight (in )gk of MP Parts in a
Typical North American Family Vehicle 1992-2004 36
Table 5.3 W European Consumption of Iron and Steel
Powders 1992-2003 (tonnes) 76
Table 3.6 West European Consumption of MP Parts and
Bearings by End Use Sector 1002 86
Table 7.3 Ferrous MP Part Production in East Europe and
the USF (tonnes) 96
Table 8.3 Japanese Iron and Steel Powder Shipments for
1990-2004 (tonnes) 96
Table 9.3 Production of Japanese MP Parts and Products
1995-2004 (tonnes) 17
Table 3.10 Iron and Steel Powder Production in China
1999-2004 27
Table 11.3 Analysis of Iron and Steel Powder Production
in China by Type of Process (tonnes) 27
Table 3.12 Estimated Ferrous-based MP Parts Production
in East Asian Countries, excluding Japan 37
Table 3.13 Estimated Consumption of Ferrous Powders in
the Southern Hemisphere (tonnes) 47
Table 3.14 Global Summary of Iron and Steel Powder
Consumption 2004 (thousands of tonnes) 57
Table 3.15 Global Summary of Iron and Steel Powder
Consumption and Forecast to 2010 (tonnes) 75
Table 3.16 North American Shipments of Stainless Steel
Powders 1990-2003 (tonnes) 78
Table 3.17 Japanese Shipments of Stainless Steel Powders
1990-2003 (tonnes) 08
Table 3.18 North American Shipments of Copper and
Copper-Based Powders 1990-2004 (tonnes) 38
Table 3.19 European Shipments of Copper and Copper-based
Powders for MP 1989-2003 (tonnes) 58
Table 3.20 Japanese Shipments of Copper Powder 1990-2004
68
(tonnes)
Table 12.3 Copper-based PM Part Production in China
1998-2004 (tonnes) 88
Table 3.22 Asia/Oceania Copper-based MP Part Production,
ex-Japan and China 1998-2004 (tonnes) 98
Table 3.23 Summary of Global Consumption of Copper and
Copper Alloy Powders 2004 (tonnes) 98
X Metal Powders
List of selbaT
Table 3.24 Global Summary of Copper and Copper Alloy
Powder Consumption and Forecasts to 2010
(tonnes) 90
Table 3.25 SU Consumption of Nickel Powder and Flake
1990-2003 (tonnes) 92
Table 3.26 Estimates of Nickel Powder and Flake Consumption
in Europe and Japan 1989-1991 (tonnes) 94
Table 3.27 Nickel Powder uses in Japan 1989-1990 (tonnes) 95
Table 3.28 Global Summary of Nickel Powder and Flake
Consumption and Forecast to 2010 (tonnes) 96
Table 3.29 North American Consumption of Tin Powder
1990-2003 (tonnes) 79
Table 3.30 Global Summary and Forecasts for Tin Powders to
2010 (tonnes) 79
Table 13.3 North American Consumption of Aluminium Powder
and Flake 1990-2003 001
Table 3.32 Breakdown of European Market for Atomized
Aluminium Powder 1991 101
Table 3.33 Global Summary of Aluminium Powder and Flake
Consumption and Forecasts to 2010 (tonnes) 201
Table 3.34 Breakdown of Tungsten Metal Applications 2003 501
Table 3.35 Breakdown of Hardmetal Tool Market in 7991
(US$ million) 701
Table 3.36 SU Shipments of Tungsten Powder and Tungsten
Carbide Powder 1990-2003 (tonnes) 801
Table 3.37 SU Net Production of Tungsten and Tungsten Carbide
Powders 1999-2003 (tonnes) 109
Table 3.38 US Imports, Exports and Consumption of Tungsten
Powders 1999-2003 (tonnes) 901
Table 3.39 Global Summary of Tungsten Powder Consumption
and Forecasts to 2010 (tonnes) 111
Table 3.40 Estimated Overall Consumption of Molybdenum by
Region 1999-2002 (tonnes) 211
Table 14.3 US Statistics for Molybdenum Powder 1990-2003:
Powder Shipments, Imports, Exports and Mill
Products made from Powder (tonnes) 114
Table 3.42 SU Molybdenum Metal Powder Statistics 1999-2003
(tonnes) 411
Table 3.43 Global Availability of Refined Cobalt 1995-2003
(tonnes) 116
Table 3.44 World Markets for Cobalt 1996-2002: Breakdown by
Application )%( 116
Table 3.45 Breakdown of Cobalt Consumption in China 2002 118
Table 3.46 Global Summary of Cobalt Powder Consumption
and Forecasts to 2010 (tonnes) 021
Table 1.4 Current Applications of Consolidated Metal Powders 121
Table 2.4 Selected Applications of Unconsolidated Metal
Powders 421
Table 3.4 North American Consumption of Metal Powders
for MP 721
Table 4.4 Estimated Breakdown of North American Metal Powder
Consumption by dnE Use 721
Table 5.4 North American Consumption of Metal Powders in
Porous Self-Lubricating Bearings 1992, 1994, 1998
(tonnes) 431
Metal Powders xi
List of Tables
Table 6.4 North American Consumption of Iron Powder for
Powder Forging 631
Table 7.4 Nominal Compositions of some Copper-based
and Iron-based Friction Materials 041
Table 8.4 Estimated Markets for MIM Parts 1999-2010
(US$ million) 341
Table 9.4 North American and European Shipments of
Welding Grade Iron Powder 1990-2003 (tonnes) 641
Table 4.10 Estimated SU Consumption of Photocopier
Powders (tonnes) 941
Table 1.5 Classification of Chemical Process Routes for
Metal Powder Production 451
Table 2.5 Summary of Current Commercial Production
Methods for Metal and Alloy Powders 161
Table 1.6 Ranking of Leading Ferrous Metal Powder
Producers by Production Capacity 212
Table 2.6 Ranking of Leading Producers of Non-Ferrous
Metal Powders by Capacity 312
xii Metal Powders
List of Figures
Figure 1.1 Metal powder applications in the modern automobile
Figure 2.1 Development of iron and copper powder production
in North America, in short tons 1940-1986 01
Figure 3.1 Production of sintered machine parts MP( structural
parts) and numbers of automobiles produced in
Japan (1961-84) 11
Figure 1.3 Breakdown of global metal powder consumption
by weight 4002 58
Figure 2.3 Breakdown of global metal powder consumption by
approximate value 2004 60
Figure 3.3 North American shipments of iron dna steel powders
1990-2003 (tonnes) 36
Figure 4.3 Breakdown of North American MP parts market 9991 46
Figure 5.3 W European consumption of iron and steel powders
1992-2003 (tonnes) 76
Figure 6.3 Japanese shipments of iron and steel powders
1990-2004 (tonnes) 07
Figure 7.3 Breakdown of MP structural parts in Japanese
vehicles 2003 17
Figure 8.3 North American shipments of stainless steel powders
1990-2003 (tonnes) 87
Figure 9.3 Japanese shipments of stainless steel powders
3002--0991 (tonnes) 80
Figure 3.10 North American shipments of copper and
copper-based powders 1990-2004 (tonnes) 84
Figure 11.3 W European shipments of copper base powders
for MP 1990-2003 85
Figure 3.12 Japanese consumption of copper powder
1990-2004 (tonnes) 78
Figure 3.13 SU consumption of nickel powder dna flake
1990-2003 (tonnes) 39
Figure 1.4 Schematic of process steps for the manufacture
of pressed-and-sintered MP parts 921
Figure 1.5 Application of metal powders sa a function of
particle size and size range 651
Metal Powders xiii
About the Author
Dr Joseph M Capus si an internationally recognized authority on metal
powders and their technology, having been involved in the industry for
the past 35 years. He has published more than 200 technical papers and
articles, and compiled or edited 10 volumes of PM conference
proceedings, sa well as contributing to the ASM Metals Handbook and
the Steel Heat Treatment Handbook. The first, second and third
editions of his industry report Metal Powders: A Global Survey of
Production, Applications and Markets were published by Elsevier
Advanced Technology in 1993, 1996 and 2000 respectively.
Born and educated in the UK, Dr Capus held research posts with INCO
Ltd and The Gillette Co before becoming technical director of Quebec
Metal Powders Ltd, one of the world's leading metal powder producers.
He has been actively involved in PM standardization at national and
international levels for over 30 years, and has co-chaired North American
sa well sa World conferences on powder metallurgy and particulate
materials. He lives in Beaconsfield, a suburb of Montr6al, Canada and
consults on powder metallurgy and advanced materials.
xiv Metal Powders
About Elsevier Advanced
Technology
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dedicated to serving the information requirements of industry and
business professionals working in a range of industrial markets. Elsevier
Advanced Technology publications provide a high-quality, reliable source
of information to professionals within engineering, materials, IT security
and energy. Products include specialist newsletters, journals and trade
magazines, technical handbooks, market reports and conferences.
Information on metal powder-related titles, including Metal Powder
Report magazine, can be found at www.metal-powder.net.
Metal Powders xv
stnenregdelwonkcA
The author si indebted to many colleagues in the powder metallurgy
industry for help with information and advice. In particular, the friendly
assistance of Peter K Johnson, formerly director, Public Relations and
Government Affairs, MPIF, and Dr Leander F Pease III, president,
Powder-Tech Associates, has been greatly appreciated. Thanks are also
due to the trade associations and journals for permission to reproduce
copyright material.
Metal powder statistics for iron and copper, and PM uses of stainless steel
powder in Japan, Japanese production statistics for PM products
(bearings, machine parts, friction materials, electrical contacts, and
miscellaneous), the analysis of demand for machine parts and for bearings
(vehicles, industrial machines, electrical machines, and other uses) and
the breakdown of machine parts for Japanese-made automobiles and
weight of PM per car, the value of Japanese-produced PM machine parts
and bearings, and the production of iron-base and copper-base PM
products and the analysis of application fields for countries in Asia and
Oceania, from the JPMA Annual stropeR ,4002-0002 are reproduced by
permission of the Japan Powder Metallurgy Association. North American
metal powder shipments and consumption statistics for 2000-2004
included in MPIF press releases and published in various issues of the
International Journal of redwoP Metallurgy (IJPM), PM industry
statistics given in country review articles for Australia, Austria, Italy,
Spain, Sweden and the Nordic countries, and the UK, published in IJPM
in 2002 and 2003, PM production statistics for South America quoted by
Donald White at the Kyoto PM World Congress in 2001 and published
in IJPM, the metal injection moulding market estimates given by Metal
Injection Molding Association president Paul Hauck and published in
MPJI in 2003, the global copper powder consumption review by Pierre
xvi Metal Powders
stnemegdelwonkcA
Taubenblat, published in IJPM in 2003, and the global market estimates
for PM High-Speed Steels quoted by Peter Johnson in MPJI in 2005, are
reproduced by permission of APMI International. European PM
production statistics and breakdowns by value, and market share by
country are reproduced by permission of the European Powder
Metallurgy Association. European PM industry statistics to 2002, quoted
by O Morandi in redwoP ygrullateM MP( 2003, 46(4), pp294-296),
titanium powder prices and market for gas-atomized titanium from an
article by Mark Hull MP( 2004, 47(1), pp12-14), PM industry statistics
for India from an article by Prof. Dube (PM2004, 47(1), pp17-28), and
PM shipment statistics for 2003 given in an address by Dr Cesar Molins,
president of EPMA, at the 2004 PM World Congress in Vienna and
reported in MP 2004, 47(4), pp309-310, are reproduced by permission
of The Institute of Materials, Minerals, and Mining. Estimated overall
consumption of molybdenum by region in 1999-2002, and commentary
on global production and consumption of molybdenum from the IMOA
website are reproduced yb permission of The International Molybdenum
Association (IMOA). The breakdown of tungsten metal applications in
2003 by region si reproduced from the ITIA website yb permission of
The International Tungsten Industry Association (ITIA). Figure 1.1,
entitled: "Metal powder applications in the modern automobile", sah
been adapted, with permission, from the chart "Powder Metal Usage on
Automobiles" published by Cincinnati Inc, Cincinnati, Ohio. Lastly, the
global sales value for lla sectors of the PM industry, and the table of
ferrous PM parts production in Russia and East Europe for 1986, 1990
and 2001/2002, from the global market review article by Bernard
Williams published in the International PM Directory (IPMD, 11th
Edition, 2004-2005, pp5-11) are reproduced by permission of MPR
Publishing Services Ltd, Shrewsbury, UK.
Finally, the author si grateful to the managements of metal powder
companies and trade organisations around the world for their help in
updating the profiles for the World Review of Metal Powder Producers in
Chapter 6.
Metal Powders xvii
yrammuS
Metal powders are just a tiny fraction of the global metals industry, yet
they play a key role in such high-profile sectors as cars and consumer
electronics. The global value of metal powder consumption has risen
since 2000 to over US$3.7 billion from close to US$3 billion. Part of
this increase si due to recently escalating primary metal prices. The
increase in overall tonnage shipped si in the order of 20% (Summary
Table 1).
Summary Table 1 Estimated Global Markets for Metal Powders
2005
Tonnes US$ (million)*
Iron and steel 1 060 000 930
Aluminium 011 000 550
Copper and Copper-base 65 500 330
Nickel 05 000 0001
Tungsten 73 000 600
Cobalt 6000 300
Tin 2600 23
*Values based on etamixorppa secirp of typical grades, in 2005 dollars
The large majority of this tonnage si made up of iron and steel, aluminium,
and copper, with the ferrous powders close to %08 of the total. Iron powder
si mostly used to make small automotive components such sa gears, cams,
sprockets, beatings, beating caps and connecting rods. The huge growth in
the consumption of ferrous powders over the past few decades has been
driven by the success in providing cost-effective, material- and energy-saving
parts production. In the powder metallurgy (PM) process, suitably
formulated metal powder blends are compacted in a die to the required
Metal Powders 1