PM Aluminium Materials
Why PM Aluminium? - Do it
Advantages of Powder Metal (PM)
Powder metal processing is a highly cost effective method of producing simple and complex parts at, or
close to, final dimensions. With tight dimensional tolerances, minimum scrap loss and fewer secondary
machining operations, PM Aluminium is uniquely positioned to provide value to its customers.
The ability to broadly control the powder constituents and process parameters allows the physical and
mechanical properties of manufactured components to be tailored to the application. In fact, material developments in Al-Si, Al-Zn and Metal Matrix Composites have allowed powder metal to provide materials
with superior properties than those available via other aluminium processing methods.
Powder metal aluminium parts have an excellent response to heat treatment, for increased wear and tensile strength. The manufacturing process also has a high level of dimensional control and reproducibility
through sizing operations.
2
t the Light Way!
Lightweight
Easy Fabrication / Machinability
Aluminium is approximately 1/3 the weight of iron,
steel, copper or brass making it the metal of choice
where mass is a concern
Aluminium is readily turned, milled or bored. In machining operations aluminium displays high cutting
speeds, smooth surface finish and allows for outstanding tool life
Strong
Surface Treatment
The strength-to-weight ratio of aluminium, outperforms
other materials. Alloying and heat treat can markedly
increase mechanical properties
Corrosion Resistant
A thin oxidized film forms on the surface when exposed to air, providing excellent corrosion resistance
For many applications no further protective or decorative coatings are required, but when needed mechanical, chemical, electrochemical, and paint finishes can
all be used. In addition, anodising treatments can enhance corrosion resistance and provide a wide range
of color variation.
Joining
Ductile at low temperatures
Unlike steel, aluminium increases in tensile strength
and retains excellent toughness at low temperature
Almost any method of joining is applicable; riveting,
welding, brazing or soldering. Adhesive bonding of
aluminium is also used in many aerospace, automotive and construction applications.
Resilient
Economically viable
Aluminium behaves elastically under static and dynamic loads. It also has excellent sound and vibration
dampening properties
Heat / Electrically Conductive
Conducts heat better than other common metals
(about 3 times that of steel). Its electrical conductivity
is approximately 62 % of copper at 1/3 the weight
Non-Magnetic
This property makes aluminium useful for electromagnetic shielding
Though aluminium materials are typically more expense than other common metals, this is often offset by a
number of direct and indirect processing and handling
costs; less weight of material used, higher machining
speed, reduced shipping weight, etc
Recyclable
Aluminium is 100 % recyclable with no downgrading
of its qualities. In addition, recycling aluminium only
requires 5 % of the energy needed to produce aluminium from raw materials.
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Aluminium Powder Metal - The Unique
Powder Metal versus Die Casting
PM has homogeneous part composition
No issues with pre-solidified material, shrink porosity or
areas of slow solidification
No large porous sections or entrapped porosity
Die castings have a fine grain structure skin (.125” thick) with
much larger grain structure in thick sections
PM has better cosmetics
No swirls or knit lines due to molten metal flow
No gate, vent scars, ejector pin marks or flash
No degradation due to heat checking on die cavities
PM has longer tool life
150k-175k shots in die casting where PM can have over a
million parts off tooling
PM tooling cost is normally a one time expense for the life
of part, where die cast can be an annual expense. This can
lead to significant savings (10-15 times the PM tooling cost)
over the part's life
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Properties of PM
PM has improved part integrity
No entrapped porosity due to die, shot tip lube or air porosity
No pre-solidified metal or alloy separation in the melt
PM has fewer process variables
No shot speed variation, shot tip wear, shot sleeve wear or
gate wear impacting flow pattern
No plugged cavity vents
No melt temperature variations or variations between
cavities
No melt cleanliness due to improper drossing or filling of furnaces
PM has less process waste
No flash, trim waste or foundry scrap
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Sintered Aluminium - Materials and Pro
Sintered aluminium presents engineers with a material solution for reduced weight, near net shape forming capability, and
a wide array of mechanical properties through various alloy
selections.
Materials are available in 2000, 6000, and 7000 series systems as well as Al-Si, Metal Matrix Composite and high density
systems which possess improved wear resistance and enhanced properties.
Properties can often be tailored through the use of a broad range of materials and processing conditions.
Sintered aluminium provides the designer an alternative processing solution over aluminium die cast, extrusions and machined parts at a competitive price.
Metal powder +
alloying elements
Mixing
1.) Raw Material
GKN offers aluminium materials in a variety of chemistries to
provide a wide range of properties to match the demanding
needs of the marketplace. Materials include 2014, 6061, 7075,
Al-14Si, and Al MMC (Aluminium Metal Matrix Composite) as
well as several developmental materials to help meet our growing customer needs. Material development is a key differentiator and we are able to offer unique aluminium compositions
and blends to our customers
Sintering
2.) Pressing/Compaction
GKN has a variety of special presses with multi-level technology to compact parts in the density range of 2.45 to 2.65 g/cm3
(88 - 95% of theoretical density). Aluminium powder is softer
than iron based powder materials which allows for compaction
at low pressures resulting in less wear and exceptional tooling
life.
Deburring/Tumbling
Sizing
3.) Sintering
For sintering the green compacts, we use precision controlled
continuous furnaces which contains lubricant burnout, sintering, and gas quench sections. Sintering temperatures are
relatively low (typically at about 600 °C) and the atmosphere
is 100% high purity nitrogen. Each furnace is capable of producing millions of parts annually.
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Secondary
operations
ocess
Unlike traditional iron PM materials, GKN has some aluminium PM compositions that densify significantly during sintering
resulting in sintered densities in excess of 98 % of theoretical
density.
4.) Homogenization/Solutionizing (optional)
Solutionizing is a heat treatment conducted just below the liquidus to homogenize the material. The parts become more
ductile after this operation which enhances their response to
subsequent sizing processes where density and strength are
enhanced.
Pressing
5.) Sizing
GKN employs sizing/coining operations as needed to densify
and meet dimensional targets and tolerances, typically to the
extent that no machining is necessary. Sizing of some materials
increases the density which enhances the mechanical properties of the part.
6.) Deburring/Tumbling
Is used to removed sharpe edges created during sizing and to
provide a uniform surface appearance, while cleaning the part
of sizing.
optional
7.) Artificial Aging (optional)
Homogenization/Solutionizing
If the parts undergo solutionizing, they are subsequently heated to low temperature for a 24 hour period to artificially age the
material and quickly build hardness and strength. This would
normally take months if the parts were left to age at room temperature.
8.) Secondary Operations
Secondary operations can include machining if dimensional
targets can't be met with sizing. They also include impregnation, anodizing, alodine, or other surface treatments.
Finished
aluminium part
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PM Aluminium - Applications
Automotive Applications
Engine Cam Caps
For automotive and Industrial applications
Unique “Z-Loc” feature that offers significant
cost benefits for cap assembly over dowel pins
Displaced aluminium die-castings
Ability to form parts with complex geometries
and oil grooves without machining
Variable Valve Train
Sprocket, Rotor and Stator
Future development
Torque Converter OWC retainer Cap
Provides required functionality while
reducing weight of the application
Stamping conversion
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Non-Automotive Applications
Corrosion resistant and lightweight
Small Engine Con Rods
Levers for Lawn and Garden applications
Bushings, spacers, latches, gears, etc.
Electronics
Hydraulic components
Thrust plates for gear pumps
Gears for external and internal (crescent and
G-rotor) pumps (current development)
Machine, Prototyping and Forging blanks
A wide variety of material blanks for machined
parts, prototype parts, and forgings
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PM Aluminium - Materials
Standard Reference I
Typical Properties (References)
Typical
Density
[g/cm3]
Hardness
HB
UTS
[MPa]
FEL
[MPa]
YS 0,2
[MPa]
EL
[%]
E
[GPa]
Al4.5Cu0.5Mg0.7Si
2.60
60
160
60
130
1.5
50
2.45 - 2.60
Al4.5Cu0.5Mg0.7Si
2.60
75
300
80
280
1
57
N/A
2.50 - 2.60
Al1.0Mg0.5Si0.2Cu
2.55
40
160
1)
100
2
N/A
2.50 - 2.60
Al1.0Mg0.5Si0.2Cu
2.55
70
240
1)
210
1
N/A
2.55 - 2.65
Al2.5Cu0.5Mg14Si
2.62
80
200
100
150
1
79
N/A
2.55 - 2.65
Al2.5Cu0.5Mg14Si
2.62
115
320
80
300
<1
79
N/A
2.74 - 2.78
Al5.5Zn1.6Cu2.5Mg
2.76
100
315
80
270
1.2
65
N/A
2.74 - 2.78
Al5.5Zn1.6Cu2.5Mg
2.76
135
420
120
410
1
65
MPIF
Density
[g/cm3]
N/A
2.45 - 2.60
N/A
Typical composition
Remark
T6 heat treated
T6 heat treated
T6 heat treated
T6 heat treated
Aluminium Metal Matrix Composite Materials (Al MMC)2)
1)
N/A
2.68 - 2.72
AlXCuXMgXCeram
2.70
100
270
1)
210
3
50
N/A
2.68 - 2.72
AlXCuXMgXCeram
2.70
110
310
1)
280
1.5
55
Being evaluated
2)
Other MMC materials are currently under development
Elongation - Total strain measured with a 25 mm gauge length extensometer that remained attached to the sample through to fracture.
FEL - Based on 10,000,000 cycles of completely reversed stress using an R.R. Moore type of instrument. Specimens prepared and
polished in accordance with ASTM standard B925-08.
Young’s Modulus - Measured in accordance with ASTM standard E111-04
Yield Strength - Measured at an offset of 0.2 % strain.
Density - Measured in accordance with ASTM standard B328-96.
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T6 heat treated
Chemical Composition (Standard)
Standard Reference II
GKN
SM Material
Code
Al
[wt.-%]
Cu
[wt.-%]
Zn
[wt.-%]
Si
[wt.-%]
Mg
[wt.-%]
Others
[wt.-%]
Bal.
4.0 - 5.0
-
0.7
0.5
<0.5
PMET AL2014
D73/E73
ACT1-2014 type II
Bal.
4.0 - 5.0
-
0.7
0.5
<0.5
PMET AL2014 T6
E73
ACT6-2014 type II
Bal.
0.2
-
0.5
1
<0.5
PMET AL6061
E73
AT1-6061 type II
Bal.
0.2
-
0.5
1
<0.5
PMET AL6061 T6
E73
AT6-6061 type II
Bal.
2.0 - 3.0
-
13 - 15
0.5
<0.5
PMET AL14Si
N/A
N/A
Bal.
2.0 - 3.0
-
13 - 15
0.5
<0.5
PMET AL14Si T6
N/A
N/A
Bal.
1.6
5.0 - 6.0
-
2.5
<1
PMET AL7075
N/A
N/A
Bal.
1.6
5.0 - 6.0
-
2.5
<1
PMET AL7075 T6
N/A
N/A
Bal.
X
-
-
X
<10
PMET ALMMC1
N/A
N/A
Bal.
X
-
-
X
<10
PMET ALMMC1 T6
N/A
N/A
UTS: Ultimate Tensile Strength
EL: Elongation
DIN 30903
SINT-
FEL: Fatigue Endurance Limit
E: Youngs Modulus
ASTM B595-95
YS: Yield Strength
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About GKN Sinter Metals
Production Countries
Argentina
Italy
GKN Sinter Metals – a wholly owned
subsidiary of U.K.-based GKN plc, a
global industrial company – is the
world’s largest producer of precision
powder metal products. With a focus
on superior delivery, quality and total
solutions, the company offers extensive technical expertise in design, testing and various process technologies.
GKN Sinter Metals offers a full range of
more than 10,000 complex shape, high
strength products for the automotive,
commercial vehicle, home appliance,
lawn and garden, office equipment,
power tool, recreational vehicle and
process industry markets.
GKN Sinter Metals de Argentina S.A.
Ruta Nac. 5 Km. 159,5
(B6622GKA) Chivilcoy – Bs. As.
Argentina
GKN Sinter Metals SpA
Fabrikstraße 5
39 031 Bruneck (BZ)
Italy
Phone:
E-mail:
Phone.
E-mail:
The company’s global footprint spans
more than 13 countries across five continents. GKN Sinter Metals is in close
proximity to its customers with more
than 30 global locations and a workforce of approximately 5,500 employees.
China
For more information about GKN’s
world of solutions visit
www.gknsintermetals.com
*54-11-5368-3700
infoargentina@gknsintermetals.com
*39-0474-570211
infoitaly@gknsintermetals.com
North America
Brazil
GKN Sinter Metals Ltda.
Av. Emancipacão, 4.500 - Santa Esmeralada
CEP 13186-542
Hortolandia – SP – Brazil
GKN Sinter Metals
3300 University Drive
Auburn Hills, Michigan 48326-2362
USA
Phone:
E-Mail:
Phone:
E-mail:
*55-19-2118-9400
infobrazil@gknsintermetals.com
Canada
GKN Sinter Metals – St. Thomas Ltd.
7 Michigan Boulevard
St. Thomas, Ontario
Canada N5P 1H1
Phone:
E-mail:
*1-519-631-4880
infona@gknsintermetals.com
*1-248-371-0800
infona@gknsintermetals.com
GKN Sinter Metals
(PM Aluminium Plant)
407 Thornburg Drive
Conover, NC 28613
Phone:
E-mail:
*1-828-466-5019
infoalum@gknsintermetals.com
South Africa
GKN Sinter Metals – Danyang
Number 7 Mechanical Industry Park
Danyang Development Zone
Danyang,
China
Phone:
E-mail:
*86-511-86-885-556
infochina@gknsintermetals.com
Phone:
E-mail:
*27-21-950-6200
infoafrica@gknsintermetals.com
GKN Sinter Metals Sales Offices Worldwide
Germany
GKN Sinter Metals Engineering GmbH
Krebsöge 10
42 477 Radevormwald
Germany
Phone :
E-mail :
GKN Sinter Metals – Cape Town
P.O.Box 156
Sacks Circle
Bellville, 7530
South Africa
*49 2191-693-0
infogermany@gknsintermetals.com
China
E-mail :
infochina@gknsintermetals.com
France
E-mail:
infofrance@gknsintermetals.com
Japan
GKN Sinter Metals Filters GmbH
Dahlienstraße 43
P.O.Box 1520
42 477 Radevormwald
Germany
E-mail:
Phone:
E-Mail:
E-mail:
*49 2195-609-27
feedback@gkn-filters.com
infojapan@gknsintermetals.com
Korea
E-mail:
infokorea@gknsintermetals.com
Spain
infospain@gknsintermetals.com
Sweden
E-mail:
India
GKN Sinter Metals Ltd.
146, Mumbai Pune Road
Pimpri, Pune 411 018
Maharashtra, India
Phone:
E-mail:
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*91-20-2742-6261, 6262, 6263
infoindia@gknsintermetals.com
infosweden@gknsintermetals.com
United Kingdom
E-mail:
infouk@gknsintermetals.com
United States
E-mail:
infona@gknsintermetals.com