Student Information

V. The Future of PM

The PM industry is expected to continue growing well into the next century.  The success of PM and hybrid PM technologies such as powder forging, hot isostatic pressing, rapid prototyping, spray forming, high temperature sintering and injection molding has propelled the industry in North America into new applications and markets.

 The value of the metal powder market in the U.S.A. in 1997 was $1.7 billion which covers metal powders, paste and flakes.  North American metal powder shipments reached 511,575mt (563,533st) in 2000.  With the continued growth in PM and the projected demand for iron powder, North American iron powder makers are gearing up by investing in new plant capacity. 

 The copper and copper-base powder markets and aluminum and stainless steel markets all experienced growth in 2000.  Applications for aluminum powder include paints and coatings, chemicals, as an alloying element, solid fuel for missiles and rockets, explosives and pyrotechnics, and PM parts and composites.  PM design engineers are interested in aluminum in the automotive market.  Applications include cam cap bearings, mirror brackets, shock absorber parts, gerotors, pumps and connecting rods.  Most of the growth in stainless steel has been in the 400 series powders because of the demand for automobile exhaust system flanges and sensor rings in ABS systems.  The use of stainless steel for PM parts in lock hardware and appliances is also growing.

 The European PM industry is also experiencing growth in all its powder markets.  The PM industry is becoming more global, consistent with the trend of global sourcing by automakers such as GM, Ford, Daimler-Chrysler, Toyota, Honda, BMW and Volkswagen.

 The North American PM parts business is estimated to exceed the $2 billion sales level from 1998, making it the largest PM market in the world.  The warm forming market continues to grow, which allows parts-makers to produce ferrous powder products with high performance characteristics in a single compaction operation.  Worldwide sales of PM parts were estimated at $5 billion in 1998.

 The recognition of PM as a strategically important technology and industry is beyond question as major customers increase their reliance upon PM, not only with the conventional side of the business, but also with advanced particulate materials.  The use of hot isostatic pressing is growing for tool steels and superalloys, and in other advanced processes like rapid prototyping, thermal spraying, cold forming and in the processing of submicron size powders.  The current annual market for superalloy powder and PM extruded bar is in the range of $35-$45 million.  End-uses are superalloy powders and PM billets for aircraft engine parts, aircraft engine repair, oilfield and petrochemical.  These applications mandate hot isostatically pressed products.

 Powder injection molding (PIM) markets are estimated to be growing at 20-25% because of improved technology, materials and binder systems.  More innovative product designs are being created from this sector of the industry.  The U.S. PIM market is estimated at $245 million - $120 million for metal injection molding and $125 million for ceramic/nonmetallic powder injection molding.

 The manufacturers of PM equipment (tooling, compacting presses, furnaces and atmospheres) have also experienced favorable growth.  Sales of equipment and atmospheres represent an annual market well above $100 million.  The trend is for larger presses with more sophisticated controls, and higher temperature furnaces, all capable of providing parts with strength and reliability. 

 Other growth sectors of the PM market include rapid prototyping, spray forming, metal matrix composites, metal foams and nanoscale powders.  2000 represented the tenth year of sustained growth, a record for the PM industry.