Special Interest Program

Title: Atomization

Program Organizers: 
Joe Strauss, FAPMI, HJE Co., Inc.
Iver Anderson,  Ames National Lab.
Chris Schade, Hoeganaes Corp.

The demand for high-performance metal powders has surged, driven by advancements in manufacturing technologies. This session provides an overview of metal powder atomization methods crucial for PM, MIM, AM, and thermal spray processes. Processes including water, gas, plasma, spinning disc, and Electrode Inert Gas Atomization (EIGA) will be reviewed. Delegates will learn how these technologies influence product properties and market dynamics, highlighting their importance in driving innovation and efficiency in metal powder manufacturing.

PMSIP 1-1          PMSIP 1-2

Title: PM Machining

Program Organizer: 
Bo Hu,  North American Höganäs Co.

PM machining is a crucial secondary operation used to achieve desired surface finishes, dimensional adjustments, and additional features. The machinability of PM components depends on material composition, manufacturing routes, microstructure, and matrix hardness. Selecting the right tools and optimizing parameters are key for maximizing tool life and productivity. This presentation explores the machinability of various PM materials, the impact of alloying elements and porosity, and the challenges of using machinability-enhancing additives, emphasizing the importance of effective laboratory testing to improve production outcomes.

PMSIP 2-1

Title: Emerging Technologies

Program Organizers: 
Blaine Stebick, Phoenix Sintered Metals LLC
Chantal Labreque, Rio Tinto Metal Powders
Roland Warzel III, North American Höganäs Co.
Scott Davis, Hoeganaes Corp.,
Tom Pelletiers, FAPMI, Kymera International

This session will explore the role of PM and particulate materials in advancing sustainable energy and electric vehicle (EV) technologies. Presentations will explore PM's importance in iron-air batteries for a clean electricity grid; discuss powder press shaping of magnetic materials for e-mobility; and address powder metal fatigue in EV drivetrains using the FKM Guideline. Additionally, opportunities will be discussed in next-generation EV drivetrains and the impact of critical minerals on the industry. Discover how these technologies shape a sustainable future.

PMSIP 3-1          PMSIP 3-2          PMSIP 3-3

Title: Powder Safety

Program Organizer: 
David R. Johnson,  North American Höganäs Co.
Doug Thomas, North American Höganäs Co.

The National Fire Protection Association (NFPA) launched NFPA 660, a standard for managing combustible dusts and particulate solids. This comprehensive framework consolidates existing guidelines and establishes protocols to enhance fire prevention and protect facilities from dust-related hazards, fires, and explosions. NFPA 660 incorporates key standards such as NFPA 61, 484, 652, 654, 655, and 664. The presentation aims to inform industry professionals about the standard's implications for safety management and regulatory compliance.

PMSIP 4-1

Title: Fatigue

Program Organizer: 
Blaine Stebick, Phoenix Sintered Metals LLC

Model-based engineering is rapidly adopted in the automotive industry, utilizing models for conceptualization, analysis, and validation of complex systems. This approach aims to reduce costs, shorten design cycles, and detect defects early, relying heavily on comprehensive material databases. However, limited mechanical property data for PM materials, particularly regarding fatigue, may hinder their selection in design phases. This presentation discusses the need for extensive fatigue data and outlines efforts to assess PM materials' performance through new testing and modeling methods.

PMSIP 5-1

Title: Applied Metallography for AM Materials

Program Organizer: 
Thomas Murphy, FAPMI, Hoeganaes Corp.

Accurate metallographic analysis of AM or PM samples requires specific preliminary conditions. The process begins by defining the analysis goals, selecting and removing the correct sample, and encapsulating it for grinding and polishing to reveal its microstructure. Various methods, including chemical and tint etchants and specialized microscopy, help examine the microstructure. Successful analysis enables insights into a part's history, processing behavior, and potential failure causes. This presentation highlights metallographic analyses of sinter-based AM and PM parts and powders.

PMSIP 6-1