E-IJPM: Vol. 44/4 - MPIF

missions contain 8.2 to 11.8 kg (18 to 26 lb.) of
PM parts. The new GM High-Feature 3.6 L V-6
DOHC engine contains about 16.3 kg (36 lb.),
which is more than the total PM parts content
was in the average U.S.-built vehicle in 1998. It is
a world engine made in Australia, Canada, Japan,
and the U.S.
Another new product is the dual-clutch transmission,
a growing product that contains about
7.2 to 8.2 kg (16 to 18 lb.) of PM parts.
The next generation of North American-built
diesel engines, scheduled for introduction during
the 2009 to 2011 timeframe, is another bright
spot. Applications include PM cam-gear drives,
idler gears, timing-system sprockets, and fuelinjector
gears. In addition, powder-forged connecting
rods and PM bearing caps are currently
undergoing validation testing. The outlook for
acceptance looks promising. Observers are forecasting
that diesels could capture 20 percent of
the North American engine market within the next
10 years.
Because of the shift away from full-size SUVs
and light trucks to crossover vehicles and cars,
the average PM content per vehicle has stabilized
in 2008 at 19.5 kg (43 lb.), the same as in 2007.
This number will improve when production volumes
are expected to normalize at an annual rate
of 15 million to 15.5 million light vehicles after the
second quarter of next year. In contrast, the average
European-built vehicle contains 10 kg (22 lb.)
of PM parts, and the average car built in Japan
about 8.6 kg (19 lb.) of PM parts, Figure 4.
Over the past year, in an effort to determine
Figure 4. Estimated weight of PM parts/components in a typical vehicle.
(1 lb. = 0.455 kg)
Volume 44, Issue 4, 2008
International Journal of Powder Metallurgy
STATE OF THE PM INDUSTRY IN NORTH AMERICA—2008
more than just the weight of PM parts in a typical
vehicle, MPIF has been working with its member
companies to assess the total number of actual
applications and total parts in a typical vehicle.
Although this extensive study is not yet finalized,
at a minimum, a typical North American car has
more than 230 different applications containing
over 750 total PM parts. Since we are still gathering
data, these numbers are conservative and will
undoubtedly increase when additional data are
collected.
THE MIM MARKET
The North American MIM market is expected to
grow in the range of 10 to 15 percent this year.
The market in 2007 is estimated at about $155
million in sales from 20 to 25 job shops. Medical
products, firearms, and hand tools are the top
three domestic markets. Only a handful of MIM
parts makers produce automotive applications,
the most important of these being turbocharger
vanes. Injection molding has been successful in
making hardmetal twist blades with a uniform
helical twist. While iron–nickel alloys and stainless
steels dominate the MIM materials mix, specialty
materials are finding applications too. These
include copper, titanium, hardmetals, soft magnetic
alloys, and superalloys.
THE PM PARTS INDUSTRY
Major acquisitions and plant closings have
pruned the PM parts business in the period since
1990 when MPIF began collecting acquisition statistics,
during which time 129 acquisitions have
been documented, Figure 5. Large multinational
corporations and various private equity groups
have purchased many entrepreneurial companies
in a consolidation trend. Less-efficient operations
have been closed or folded into larger plants.
Rationalization of products has occurred where
specific long-run parts are fed into dedicated
plants with automated production lines.
Companies have also relinquished marginally
profitable parts.
Industry companies can be grouped into four
categories: Tier 1—annual sales >$200 million;
Tier 2—annual sales of $75 to $200 million; Tier
3—annual sales of $25 to $75 million; and Tier
4—annual sales