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The PoP Centre Primed to help you imagine new possibilities
The PoP CentrePrimed to help you imagine new possibilities
© Höganäs AB (publ.), December 2012. 0299HOG Höganäs AB (publ.) | SE-263 83 Höganäs | SwedenPhone +46 42 33 80 00 | Fax +46 42 33 83 60www.hoganas.com
The PoP Centre
Our common goal is to grow the world of metal powders.
Höganäs wants to contribute to our industry reaching its full
potential. We think this can only be done by working together.
Future success is to be found in the close interaction between
application knowledge, design aspects, process and powder
materials. We hope that our PoP Centre will become a place
where Höganäs and its partners can join forces, in close
cooperation, to innovate and drive the business forward.
Here we have the infrastructure to work with material
development, application design and prototyping as
well as process optimisation, an ideal platform for joint
application engineering within the areas of PM components,
electromagnetic applications, surface coating and many other
powder application segments. You can use the Centre as a
source of inspiring ideas and employ its services to develop,
test and rapidly prototype new concepts. Through partnership
we can push the limits of the powder technology, improve
performance, win new applications and expand markets.
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The vision of the PoP Centre is to make metal powder technology the first choice by helping customers and end-users to utilise the Power of Powder®.
Powder products are developed and manufactured for several
different segments by Höganäs worldwide:
• Components sintered components, soft magnetic
composites, friction, filters, metal
injection moulding
• Surfacecoating laser cladding, thermal spraying
• Joining brazing, welding
These product segments will now be supported by the PoP
Centre to provide a more integrated development approach
for products and solutions. The services range from straight-
forward prototyping or mechanical testing to complete
application development as exemplified by SMC (Soft Magnetic
Composites) where support encompasses material selection,
application design and process solutions.
The Centre provides a good platform for working in teams
in the whole value chain – a key to profitable growth.
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The materials expertise to select
the right powder solution.
The process know-how
to ensure optimum production
efficiency and quality.
The design support
to create innovative
applications.
The PoP Centre’s service categories:
Testing ........................................................................... 4
Material Analysis .......................................................... 6
Component Testing ..................................................... 8
ProcessDevelopment ................................................ 10
Compaction .............................................................. 12
Sintering .................................................................... 14
Machinability ............................................................. 16
ApplicationDevelopment .......................................... 18
Brazing Applications .................................................. 20
Electromagnetic Applications .................................... 22
Laser Cladding .......................................................... 24
Prototyping .................................................................. 26
Off-tool Sampling ...................................................... 28
Novel Sintering and Heat Treatment Process ............. 30
Training ........................................................................ 32
Testing
Makingiteasiertoselecttheright
powder-basedproduct
Material characterisation and testing has traditionally been
one of the strongest competencies that Höganäs offers.
By adding new component test methods such as wear
testing to established competence in areas like fatigue
analysis, the PoP Centre can provide a wide range
of material and component testing methods.
• Mechanicaltesting static properties, dynamic
properties, wear
• Materialanalysis metallographic analysis,
powder properties, rheology,
phase transfer analysis
• Chemicaltesting corrosion testing, wet chemical
analysis, material composition,
compound analysis
• Componenttesting gear strength testing, wear testing
Advanced testing methods enable “virtual” prototyping and the
generation of reliable application-relevant data to product and
process designers.
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Comprehensive facilities for testing mechanical properties.
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PM has a unique advantage over conventional manufacturing processes – the ability to design microstructures. Our facilities for metallography-based material analysis can help you realise the full design potential of powder metal.
Analysis for predicting material performance.
Material Analysis
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Makingtherightmaterialselection
Using Höganäs’ materials knowledge and microstructure
analysis tools makes it possible to design materials with
specific properties and to select the right material and
processing for a given application. Microstructure analysis also
has a troubleshooting role, providing the insight to identify root
causes for application failures and the ability to indicate
corrections to processes and materials that will ensure robust
manufacturing.
Fullspectrumofmicrostructureanalysistools
The PoP Centre gives you access to our complete spectrum
of analysis tools and investigation methods, allowing you
to utilise microstructure analysis both for developing the
innovative PM part designs of tomorrow and solving today’s
immediate component quality problems. We also arrange
courses on metallography to spread knowledge and
understanding on the potential and behaviour of PM materials.
Microstructureandthebigpicture
Utilising our resources to find out more about component
microstructure can bring you a range of benefits, both in the
short and long-term. These range from the rapid solution of
emergency component quality problems and fast identification
of failure root causes to providing the in-depth analysis to
ensure a high quality standard for powder solutions, which
helps to improve the big picture for the PM industry.
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For a range of components, such as gears and cam lobes, fatigue and wear testing is vital in order to give designers reliable design information. The PoP Centre offers a new source for application-relevant wear and fatigue data.
Obtainreliablefatigueandweardata
At present CAD and CAM technologies cannot cover important
aspects of engineering design such as contact fatigue and
wear. It can be difficult for component designers to find wear
and fatigue test data relevant to their target application. The
PoP Centre provides a new way to fill this information gap by
offering fatigue and wear testing as well as access to a range
of other testing methods.
Newweartestingcapability
The PoP Centre provides an efficient fatigue analysis service
based on many years’ experience of fatigue testing and proven
gear tooth bending test methods. Gear pitting resistance
testing is carried out on a test rig that has been specially
developed in-house. New testing facilities at the PoP Centre
mean Höganäs is offering adhesive friction/wear testing and
abrasive wear testing for the first time.
Component Testing
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Easierselectionofmaterials
Component fatigue and wear testing can give you relevant
and reliable component design data and provide an efficient
route to the performance ranking of materials/processes,
making it easier to choose a suitable powder solution. The
testing service can be used with the PoP Centre’s other
capabilities as a part of your development process to achieve
new PM applications in fatigue and wear environments.
Use our expertise and experience in component testing.
Increasingcompetitiveness
New developments in sintering provide opportunities for
the controlled sintering of high-performance powders such as
chromium materials. Cooperation with press and tool
manufacturers on the use of our Starmix® BOOST press-
ready mix has improved the productivity and quality of PM
components.
The PoP Centre will provide services that aim to optimise
customer processes in areas such as pressing and sintering,
and post treatment stages like machining.
In the past, Höganäs has developed processes such as warm compaction for its customers and we continue to be involved in joint projects to offer new alternatives and improve processing performance.
ProcessDevelopment
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Work with process development.
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Optimisingcompaction
Compaction’s crucial role in PM component production means
optimisation of the compaction process is vital for achieving
wider industry aims such as improved productivity, densities,
precision and performance. To support you in the optimising
of pressing parameters and to provide a service for the rapid
production of blanks, the PoP Centre has installed a new
fully hydraulic, multi-level Dorst 800-ton press.
State-of-the-artpressingtechnology
The Centre gives you access to state-of-the-art compaction
capacity. Besides compacting multi-level components, we
can also offer to compact blanks of different sizes and
shapes such as disks, rings and rectangular samples in
tailored-made materials that can then be used in the
prototyping process. You can also gain access to other
smaller presses – a 45-ton mechanical press and 120 or
400-ton hydraulic presses.
The PoP Centre can simulate real-life compaction conditions, enabling the testing of lubricants and new powder compositions, optimisation of pressing parameters and fast delivery of green or sintered blanks.
Compaction
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Comprehensivecompactionanalysis
Providing production-like compaction conditions offers
you a unique opportunity for monitoring parameters such
as different forces, part temperature, weight scatter and
ejection energy in a production rate process. The Centre
combines new and existing compaction capabilities to offer
you an effective, cost-effective service for selecting the
right powder formulation, most suitable mix composition
and press parameters for your application.
Look at compaction from all angles.
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Greater control of the sintering process is within reach.
The quality of any PM product is directly related to control of process parameters. The PoP Centre brings together a range of services to ensure you can achieve successful control of the sintering process.
Sintering
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Optimisingthesinteringprocess
We can help you to get the most out of your sintering process
by identifying the most suitable process conditions for
optimising the material performance for your application.
Process tests on your material can be carried out in robust
conditions on Höganäs’ sintering equipment. We also offer
quality assurance testing (with controlled atmospheres) of high-
performance alloyed powders such as chromium materials.
Improvingsinteringcontrol
Our equipment and services include Sinterflex, a new
technology jointly developed by Linde AG and Höganäs,
for enhanced control and monitoring of the sintering
atmosphere for alloyed powders. Prototypes produced
via the PoP Centre can be sintered under your recommended
controlled atmosphere. There is also an option to use our
metallographic investigation resources to verify a sintering
atmosphere’s effects.
Allaspectsofsinteringsupport
The full range of sintering services includes a troubleshooting
team that can investigate disturbances in your sintering
process, and training courses in sintering arranged as internal
seminars at your site or at our PM School. Utilising our
sintering support services will help you achieve smooth,
cost-efficient sintering processes optimised for your specific
applications.
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Improving the machinability of PM steels can make PM components more competitive. Using the PoP Centre’s machinability testing services can help you boost productivity and reduce machining costs.
Machinability
Machining of PM component.
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The CNC turning lathe.
Insightoncuttingparameters
The machinability of PM materials, such as sintered or
sinter hardened PM steels, is not generally regarded as being
comparable to conventional steels. Our challenge is to gain
insights on machinability that enable us to optimise key cutting
parameters – additive enhancers, tool grades and geometries,
speed and feed rates – for specific PM materials and thus
improve machinability.
Enhancemachiningperformance
The Centre’s capabilities can help you evaluate and identify the
most suitable material, process and machining enhancers to
achieve the best possible machining performance. At the heart
of our machinability analysis resources is a CNC turning
lathe and a 5-axis CNC vertical machining centre, which can
perform turning, drilling or milling tests, providing data on a
range of key machining parameters.
Morecost-efficientmachining
Detailed insight on a PM material’s machinability can enable
you to create the optimum overall conditions for machining.
This knowledge is valuable for your production process in
two respects; by making it easier and faster to solve any
machining-related problems, and by enhancing the efficiency
of machining routines, making it possible to reduce machining
costs, increase productivity and prolong tool life.
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Heat exchangers, food fortification, electric motor parts, automotive
components - the diversity of powder metal applications is endless...
If the PM industry is to grow, cooperation is needed to find new markets, convert opportunities and optimise existing solutions. You can utilise the PoP Centre’s range of services to support innovative application development.
ApplicationDevelopment
Highlightingtheopportunities
One of the PoP Centre’s important roles is to help you identify
new conversion opportunities. Recent system teardowns have
shown conversion potential in applications ranging from power
tools and lawn mowers to all-terrain vehicles. Our test car with
a converted gearbox is one example. After more than 100,000
km on the roads it has shown that PM transmission gears are
ready to meet automotive industry needs. Another example is
our 4th transmission PM gear pair which was used in a 300 HP
rally car under the toughest driving conditions.
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Applyingourservices
All the Centre’s services can be drawn on for application
development, but the most relevant are system teardowns,
market scanning, concept development, component
prototyping and “PM-ification”. The PM-ification process offers
full-chain development for conversion candidates from idea
through design support to fully functional prototypes, resulting
in a more PM-suitable, ready-to-test component.
Pursuingthepossibilities
The PoP Centre’s capabilities to help you explore new
application opportunities relate not only to PM components,
but also to brazing, surface coating, SMC and all other
powder product segments covered by Höganäs. Our
partnership can assist you in identifying new openings and
gaining the proof of concept needed to pursue applications
that create new business and expand markets.
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Brazing Applications
Customersupporteverystepoftheway
We provide customer support every step of the way. We
are deeply involved prior to product delivery, offering expert
development advice to ensure an optimum solution. On-site
application development is also provided to ensure we find the
optimum application solution for your components.
Forallkindsofapplicationtechniques
No matter what your brazing requirements are, we provide you
with support leading to successful results. Our roller-coating
equipment can help you achieve thin coatings on, for instance,
flexible fins or structured plates. With our screen printer, you can
selectively apply paste to where it is required. When you are
looking for simple and clean paste application on heat exchangers
we can help you find the optimum dispensing solution.
With state-of-the-art equipment for screen printing, roller coating and dispensing, we can help you reach high precision, high productivity and low defect rates in all types of brazing applications requiring nickel-braze alloy properties.
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Provingproductionconcepts
The roller coater, screen printer and dispensing unit in the
PoP Centre can all be integrated in mass production with
parameters targeted to customers’ processes. We can provide
test series of components with paste applied the same way
as in final production in order to make sure the customer’s
productivity and quality requirements are fulfilled.
Screen printing.
Acompetitivealternative
Soft Magnetic Composites (SMC) challenge traditional
materials in applications with alternating magnetic fields.
With unique magnetic properties in 3 dimensions and net
shaping capabilities, Somaloy® – the SMC concept brand from
Höganäs – is a competitive alternative to electrical steels in
applications such as rotating and linear machines, sensors,
fast switching solenoids and inductive components.
Fromconcepttocommercialreality
SMC has great potential, but the main challenge is to take
electromagnetic applications from concept to commercial
reality. This requires a multidisciplinary approach focusing on
material selection, application design and an efficient solution
for producing the pressed, heat-treated components. We offer
you the know-how, tools, equipment and services to support a
successful project outcome.
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Electromagnetic Applications
SMC technology opens up new opportunities to design compact, cost-efficient electromagnetic applications. With the PoP Centre, we can provide the know-how and services needed to reduce time to market for innovative SMC projects.
Fullserviceforelectromagneticapplications
Our range of capabilities provides market support in areas
such as material selection, training and prototyping. It enables
effective partnerships in dedicated application projects
providing support on application design using FEA analysis,
production optimisation, and the building and testing of new
electromagnetic applications.
Delivering innovative solutions based on specific market requirements.
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Enhancingsurfaceproperties
A number of surface coating techniques can be used to
enhance surface properties such as wear and corrosion
resistance. Laser cladding, used in industries such as oil
drilling, mining and power generation, is a build-up welding
technique that applies the coating via a molten phase.
Materials used in laser cladding, generally nickel, cobalt or
iron-based, provide surface coatings with good protection
against corrosion and wear.
Developingapplications
We can support you in all aspects of application development.
This can cover identification of the best solution to improve
component lifetime, selecting the optimum process and
material, providing you with prototypes or applying the coating
directly on your existing product. We can also back you up
with technical support on process parameters and materials,
and provide a troubleshooting service.
Surface coatings offer a potential growth area for the PM industry. Höganäs provides a full application development service for high-tech, powder metal-based surface coating methods such as laser cladding.
Laser Cladding
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Laser cladding is an advanced solution for superior wear and corrosion resistance.
Improvingresistance
As well as laser cladding, Höganäs powders are suitable for
high-tech surface coating methods such as Plasma Transferred
Arc (PTA) surfacing, High-Velocity Oxy-Fuel (HVOF), plasma or
flame spraying and powder welding. With our services you can
identify, develop, prototype and test competitive cost-effective
solutions that improve wear and corrosion resistance and open
the way to new applications.
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Anewalternativeforprototypegeneration
Customers and end-users often face a number of challenges
in developing new PM applications. Prototypes made from
pressing tools can involve high costs, considerable first step
in confirming component performance, considerable risk and
long lead times. The capabilities of the PoP Centre offer a new,
fast and cost-effective alternative for generating advanced PM
prototypes for new application developments.
Would you like to speed up the component prototyping process and reduce the risk and cost involved? Our rapid prototyping service helps you evaluate and verify component concepts faster and cut time to market.
Prototyping
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Acompleteprototypingservice
We can offer support and services every step of the way – from
concept stage to ready-to-test prototypes. Our in-house CAD
and FEA capabilities can assist in optimising key component
design aspects. The optimised CAD solution can then be
connected to our 5-axis CNC machining centre for rapid
production of prototypes from sintered pucks for testing or
design verification.
Atoolboxforyourdevelopmentneeds
You can use our material selection expertise, design support
and machining & testing capabilities to identify the optimum
process-design-material combination for your application
– a process that can help you reduce the number of design
iterations. Our services offer you the opportunity to confirm real
component performance and reduce the time, cost and risks
usually associated with development.
Advanced CAD and FEA support optimises component design.
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Anewalternativeforproductiontrials
Meeting OEM delivery times while striving for best possible
equipment utilisation and quick tool changes are common
customer challenges. The results are often a lack of both
time and suitable in-house equipment for new application
development or production trials. Besides PM material
competencies, we can provide external development
capabilities in the PoP Centre, including various pressing and
sintering capacities at your service.
Alladjacentservices
We provide the most suitable powder formulations, including
access to latest lubricant and additive developments, press
capacity up to 800 tons (CNC, multilevel, helical gear adaptor)
and much more. All commonly used sintering atmospheres
and temperatures are available and necessary density and
metallographic evaluation services are provided on site.
Want to test new design concepts or challenging compaction jobs without troubling your production? Employ external test capabilities and press technology to verify and optimise compaction feasibility.
Off-tool Sampling
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Toolingandadaptationsupportfromtheexperts
Bring your own tooling and compaction experts or benefit from
our partnership with industry leading PM tool expert Alvier AG
PM-Technology and press manufacturer Dorst Technologies.
With our combined team of experts your own shop floor can
be extended and your project a success. Our services can help
you proove a new PM concept or to off-tool real prototypes
while reducing time, cost and risks without troubling your own
shop floor.
Helical gear compaction tool.
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Novel sintering and heat treatment process
High-strength applications provide a great potential to grow the PM industry but may require special processes. The PoP Centre’s new sintering and heat treatment furnace enables cost effective surface hardening of chromium alloyed PM components.
Sintering and heat treatment furnace from ECM Technologies.
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Pilotproductionofhigh-performanceapplications
Höganäs’ unique chromium alloyed powders provide cost-
efficient solutions for high-performance applications such
as transmission gears. However, chromium alloyed PM
components cannot be heat treated by conventional gas
carburising and oil quenching. Low pressure carburising (LPC)
and gas quenching facilitates surface hardening of components
based on such powders and helps meet stringent requirements
on quality and dimensional accuracy. The PoP Centre’s state-
of-the-art furnace from ECM Technologies enables high-
temperature sintering and hardening of PM parts in pilot scale.
The combined process saves both costs and energy by
eliminating the cooling and re-heating stages required
by conventional gas carburising and oil quenching. The
technology offers further environmental advantages by
decreasing C02 emissions from the process gases and by
avoiding disposals of quenching oils and cleaning chemicals.
With state-of-the-art pilot production capacity in both
compaction and sintering, the PoP Centre is ready to develop
your next generation of high-performance PM applications that
can help grow the market for powder technology.
Höganäs has arranged many “PM Schools” over the years. Other courses cover areas such as Brazing, SMC, Surface Coating and Metallography. All courses are customised according to the customer’s needs.
Training
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•Please contact your local sales representative.
Find your local office at www.hoganas.com.
•For general enquiries, you can also email to:
ContactthePoPCentre
www.hoganas.com
Sweden
Brazil
China
France
Germany
India
Italy
Höganäs ABHöganäsPhone +46 42 33 80 [email protected]
Höganäs Brasil LtdaMogi das CruzesPhone +55 11 4793 [email protected]
Höganäs (China) Co. LtdShanghai Phone +86 21 670 010 [email protected]
Höganäs France S.A.S.Villefranche-sur-Saône CedexPhone +33 474 02 97 [email protected]
Höganäs GmbHDüsseldorfPhone +49 211 99 17 [email protected]
Höganäs India Pvt LtdPune Phone +91 20 66 03 01 [email protected]
Höganäs Italia S.r.l.Rapallo (Genoa)Phone +39 0185 23 00 [email protected]
Japan
Rep.ofKorea
Russia
Spain
Taiwan
UnitedKingdom
UnitedStates
Höganäs Japan K.K.Tokyo Phone +81 3 3582 [email protected]
Höganäs Korea LtdSeoul Phone +82 2 511 43 [email protected]
Höganäs East Europe LLCSaint PetersburgPhone +7 812 334 25 [email protected]
Höganäs Ibérica S.A.MadridPhone +34 91 708 05 [email protected]
Höganäs Taiwan LtdTaipei Phone +886 2 2543 [email protected]
Höganäs (Great Britain) LtdTonbridge, Kent Phone +44 1732 377 [email protected]
North American Höganäs, Inc.Hollsopple: PAPhone +1 814 479 [email protected]
