Powder metallurgy is a manufacturing process that’s a leading candidate for both prototype and end-use parts across an increasing range of industries. More design engineers are turning this technology because of its ability to provide a low-cost or better-performing part. But there's another reason the powder metallurgy process has become popular -- out of necessity.
One of the most attractive aspects of powder metallurgy (PM) is how it's a green technology. This is a term thrown around by many companies, and it can mean a few different things.
Specific to powder metal, there are three key characteristics that make it more eco-friendly compared to conventional metal forming processes. Here’s how powder metallurgy green technology is defined in 2020:
Powder metal is poised to be part of a sustainable future for electric vehicle design. Here are three ways it’s already contributing:
Powder metallurgy is pro-sustainability right from the beginning. The metal powder your manufacturer starts with is mainly created via recycled scrap steel.
Compared to conventional manufacturing technologies like casting and forging, the powder metallurgy and sintering process uses about 15% less energy. It’s easy to explain these energy savings -- there’s simply far less need for secondary operations in powder metallurgy.
Some of the process steps that can be eliminated with PM include:
Everything above creates scrap. Eliminating or reducing these makes the factory a more sustainable operation while adding the bonus of saving you money and reducing lead time.
The efficiency of the process only trends upward from there.
The scrap rate of PM is only about 3% -- significantly less than conventional processes where metal is cut away rather than “added” or “built up.”
While it's true that you occasionally need a secondary operation in powder metallurgy to reach your end goal, it’ll have little effect on your scrap rate. Bottom line: PM only uses the amount of material that’s required to create the end part.
The powder metallurgy process creates components that are sustainable in two notable ways.
Heightened emissions standards in Europe, Asia, California, and elsewhere have increased the need for more efficient vehicles through the use of “electrification.” By using advanced materials and processes, powder metal parts can create a new standard in electric motor efficiency.
And as more consumers demand eco-friendly vehicles and automakers invest their efforts in them, powder metallurgy parts have the potential to help meet and exceed their short- and long-term goals.
Powder metallurgy’s 3D shape-making ability improves efficiency in another way: It saves space and weight. Because you can create unique, complex geometries, you can use less material and take up less space in the vehicle’s design. If the part is sintered at high temperatures, it can maintain high strength despite being lightweight. Lighter vehicles are, of course, going to use less fuel -- a win-win both for manufacturer and consumer.
And while the cost of powder metallurgy may initially be greater than that of conventional methods, you'll save money in other ways. The net shaping capability allows for composite shapes that consolidate a design. You might just be able to turn a three-part assembly into a single part!
Beyond automotive motors, powder metal components can pay big dividends in other types of electric motors. Check out this case study of ceiling fans.
The final advantage of powder metallurgy is more on the consumer’s side -- low energy use.
Today’s consumer can buy an electric-intensive vehicle providing creating greater comfort and performance with additional advantages in total cost of ownership.
The powder metallurgy process is simple, yet highly involved. You melt the steel, then press and sinter. Your manufacturer can efficiently pump out high volumes of parts and assemblies with reduced weight, greater magnetic qualities, and compact design.
Material and process efficiency is only part of the debate between powder metallurgy and competing process. Learn more about the advantages and disadvantages of “conventional” powder metallurgy vs. forging, machining, casting, metal injection molding, 3D printing, stamping, and electrical steel laminations by downloading the free e-book below: