E-IJPM: Vol. 44/4 - MPIF

POWDER METALLURGY IN INDIA
38
Copper powder is produced by numerous
firms.1–4 The initial hurdle of precise quality control
for press-and-sinter grade powders has been
overcome. P.P. Patel & Co., which began production
in 1996, has grown considerably over recent
years. The plant is located near Solapur,
Maharashtra State. The product ranges from copper
powder of differing compressibilities, bronze,
lead, tin, zinc, and powders for cutting and grinding
tools. The plant has gas-atomization capability,
controlled-atmosphere furnaces, rod mills, and
other facilities, and a fully equipped laboratory.
Sarda Industrial Enterprises, Jaipur, Rajasthan
State, has been producing nonferrous powders
since 1982. Electrolytic copper powder is the
major product, for which virgin copper cathodes
(99.9% purity) are the starting material. The company
has plans to produce atomized copper-alloy
powders and gold bronze powders.
Shield Alloys (India) Pvt. Ltd., Mumbai, produces
a variety of electrodes. These include
super-low-heat-input tubular hardfacing electrode
sticks, which contain chromium and complex
carbide powders. The electrodes are suitable
for high deposition rates (up to 4 kg/h weld metal)
with minimum penetration.
PRODUCTION OF PM PARTS
Major PM parts produced are filters, self-lubricating
bearings, and parts used in automotive,
home appliance, and office equipment. The range
of materials embraces ferrous and copper-base
alloys. Post-sintering treatments such as steam
and heat treatment are frequently carried out.
Hot-worked molybdenum and tungsten alloy PM
products are produced by Mishra Dhatu Nigam
(MIDHANI), a plant run by the Department of
Defense Production and Supplies, Ministry of
Defense. A need for other hot-worked structural
materials, for example, aluminum, and copperbase
alloys, exists but the necessary investment
for indigenous production is not yet forthcoming.
The biggest PM parts producer in India is GKN
Sinter Metals Ltd., Pune, previously known as
Mahindra Sintered Products Ltd. In April 2002,
GKN bought a minor stake (49%) of Mahindra and
Mahindra. The company also manufactures custom-designed
valve-train components via technical
collaboration with Nippon Piston Ring Co., Japan.
The plant operates a number of compacting presses
(3–650 mt) served by an in-house tool room
complete with a CAD/CAM facility. It also houses
mesh-belt furnaces, high-temperature pusher furnaces,
and continuous steam-treatment and hardening
production lines. It has QS-9000 and ISO
14001 certification. The plant is comparable with
any PM plants worldwide. The long history of production
from this company has indirectly helped
various smaller PM players in India in terms of
technical manpower. There is a general concern in
the local PM community that multinational companies
have become too inward looking.
The second major PM parts producer in India is
Sundaram Fasteners Limited, Metal Form
Division, Hosur, Tamil Nadu State (40 km south of
Bangalore). It is part of the TV Sundaram group of
companies, the largest automotive component
manufacturing group in India. PM accounts for
21% of the division’s output. The company also
has an iron powder plant at Hyderabad with
~5,400 mt annual capacity. The main PM plant in
Hosur has 25 compacting presses up to 500 mt
capacity, 12 sizing presses up to 630 mt capacity,
and seven sintering furnaces (maximum temperature
1,130°C). The group formed a joint venture,
Sundaram Bleistahl Private Ltd., with Bleistahl
GmbH, Germany, in 2004 to make PM valve-train
parts, in which Sundaram has a 76% equity stake.
Federal Mogul Goetze (India) Limited–Sintered
Products Division, established in 1996, is a joint
venture between Federal–Mogul Sintered Products
Limited, U.K. (formerly Brico), and Goetze India
Ltd. The plant specializes in PM engine and transmission
components for automotive applications
and is situated about 100 km south of Delhi. The
plant has 12 compacting presses and two sintering
furnaces. Specialty Sintered Products Ltd.,
near Pune, is a relatively new addition. The plant
has compacting press capacity of 5–200 mt. The
maximum density of the parts is 7.4 g/cm 3 .
Sinter hardening and carbonitriding facilities are
also available. Precision Sintered Products Ltd.,
located in Rajkot, Gujarat State, has produced
sintered parts since 1997. Primary products are
bushes, outer inner rotors, and gears. Star
Sintered Group has three production plants in
Noida near Delhi, namely Star Sintered Products
Ltd., Standard Sintered Products Pvt. Ltd., and
Gold Star Filters Pvt. Ltd. Recently the group
acquired Sinter Kings Virmani, a Delhi PM company.
Production capacity has increased from 3
mt/day to 10 mt/day in one year. In all, the group
has 30 compacting presses up to 400 mt capacity,
10 sizing presses, and six sintering furnaces.
Volume 44, Issue 4, 2008
International Journal of Powder Metallurgy