european powder

metallurgy association
Promoting Powder Metallurgy Technology

Hard New
Metal
Additive Functional Materials and Hot Isostatic Materials, Press and
Injection
Manufacturing Materials Diamond Pressing Processes and Sinter
Moulding
Tools Applications

Spotlight on PM
Case Studies: Energy
A booklet containing a selection of Powder
Metallurgy Component Case Studies

1st Edition

www.epma.com/spotlightonpm
 european powder
metallurgy association
Promoting Powder Metallurgy Technology

For more information on

Powder Metallurgy
Introduction to
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Introduction to
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Introduction to
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 Medical

CONTENTS
INTRODUCTION.......................................................................................................................................... 4
KEY..................................................................................................................................................................... 4
BURNER REPAIR............................................................................................................................................ 5
FUEL BURNER................................................................................................................................................ 5
HEAT EXCHANGER..................................................................................................................................... 6
ROTARY STEERABLE SYSTEM................................................................................................................... 6
STATOR SEGMENT OF AXIAL COMPRESSOR................................................................................... 7
STIRLING REGENERATOR......................................................................................................................... 7
TWISTER USED IN AN AIR EXTRACTION PUMP............................................................................. 8

Promoting Powder Metallurgy Technology

COMPOUND RAISER PIPE FOR OIL REFINERY CRACKING PLANT........................................ 8
IMPELLER FOR GAS COMPRESSOR....................................................................................................... 9
MANIFOLD FOR TOPSIDE AND SUBSEA STATIONS....................................................................... 9
NNS REACTOR COOLANT PUMP IMPELLER.................................................................................. 10
ROTOR FOR STEAM AND GAS TURBINE.......................................................................................... 10
SWIVEL FOR OFFSHORE INDUSTRY.................................................................................................. 11
VALVE BODY FOR OFFSHORE SUBSEA STATIONS........................................................................ 11
WYE-PIECE FOR OFFSHORE SUBSEA STATION............................................................................. 12

Other EPMA Case Study booklets are available

european powder european powder european powder
metallurgy association metallurgy association metallurgy association
Promoting Powder Metallurgy Technology

Promoting Powder Metallurgy Technology

Promoting Powder Metallurgy Technology

Hard New Hard New Hard New

Metal Metal Metal
Additive Functional Materials and Hot Isostatic Materials, Press and Additive Functional Materials and Hot Isostatic Materials, Press and Additive Functional Materials and Hot Isostatic Materials, Press and
Injection Injection Injection
Manufacturing Materials Diamond Pressing Processes and Sinter Manufacturing Materials Diamond Pressing Processes and Sinter Manufacturing Materials Diamond Pressing Processes and Sinter
Moulding Moulding Moulding
Tools Applications Tools Applications Tools Applications

Spotlight on PM Spotlight on PM Spotlight on PM

Case Studies: Aerospace Case Studies: Automotive Case Studies: Medical
A booklet containing a selection of Powder A booklet containing a selection of Powder A booklet containing a selection of Powder
Metallurgy Component Case Studies Metallurgy Component Case Studies Metallurgy Component Case Studies

1st Edition 1st Edition

1st Edition

www.epma.com/spotlightonpm www.epma.com/spotlightonpm
www.epma.com/spotlightonpm

AEROSPACE AUTOMOTIVE MEDICAL

Download at www.epma.com/publications

The information in this booklet is provided by third parties and although EPMA does its best to
ensure the case studies are accurate it is not liable for any mistakes or wrong information. E&OE

www.epma.com/spotlightonpm 3
 Spotlight on PM

INTRODUCTION
Powder Metallurgy (PM) is a continuously and rapidly evolving technology embracing most
metallic and alloy materials and a wide variety of shapes. Powder Metallurgy is a highly developed
method of manufacturing reliable ferrous and non-ferrous parts. The European Market alone
has a turnover of over €6 billion per year, with annual worldwide metal powder production
exceeding one million tonnes.
PM Components are created by mixing elemental or alloy powders and compacting the mixture
in a die, with the resultant shapes heated or ‘sintered’ in a controlled atmosphere furnace
to bond the particles metallurgically. The high precision forming capability of PM generates
components with near net shape, intricate features and good dimensional precision pieces.
Promoting Powder Metallurgy Technology

Pieces are often finished without the need of machining.

Whether it is by controlling porosity to develop the unique capability of self-lubrication or by
optimising the chemistry to provide improved longevity in wear parts, PM has a solution.
The benefits of using PM Components include:
• Structural pieces with complex shapes
• Special properties such as hardness and wear resistance
• Great precision and good surface finish
• Large series of pieces with narrow tolerances
• Controlled porosity
• Reduced component weight
The case studies shown in this publication are examples of the wide range of PM products,
materials and applications that are in current production. Each and every day a new PM part helps
a company to open up new market opportunities.
These case studies comprise of the following processes Additive Manufacturing and Hot Isostatic
Pressing.

KEY
AM HIP

ADDITIVE HOT ISOSTATIC

MANUFACTURING PRESSING
Pages 5-8 Pages 8-12

If you would you like your case study to be included in future

editions of this booklet or one of our case study booklets on a
different sector please contact marketing@epma.com

Copyright © European Powder Metallurgy Association. 1st Edition 2019

4 www.epma.com/spotlightonpm
 Medical

BURNER REPAIR
Material: Nickel alloy HX
Process used: Laser Beam Melting

Description: Customised using EOSINT HM280 machine for precise, cost-effective, and faster
repair of worn burner tips of gas turbines exposed to extreme temperatures.
Benefits:
•

Promoting Powder Metallurgy Technology

Time required for the repair process of burner tips has fallen by more than 90%
• Old burner versions can quickly be brought up to the latest standards of technology
• Potential cost reductions already seen at an early stage

Siemens Industrial COST

Turbomachinery AB AM SAVING

FUEL BURNER
Material: Nickel base 718
Part dimensions (cm): 3.5 x 5
Process used: Laser Beam Melting

Description: Produced on an EOS HM290, this multi-fuel burner was developed with an
optimized footprint and functionality.
Benefits:
• Use of gaseous/liquid fuels
• Efficient use of difficult to burn fuels
• Reduction of combustion chamber by 20%
• Low unit costs despite small batch sizes
• Reduced nitrous oxide emissions

IMPROVED
Euro-K AM PERFORMANCE

www.epma.com/spotlightonpm 5
 Spotlight on PM

HEAT EXCHANGER
Material: Nickel base 718
Part size (mm): 80 x 38 x 19
Process used: Laser Beam Melting

Description: This heat exchanger was designed within the HELMETH FP7 Project, to operate
at high temperature and under high pressure in a severely aggressive atmosphere (with H2 and
O2). Each side of the heat exchanger has three channels, and inside the channels longitudinal
triangular fins have been inserted in order to act as fins for the enhancement of the heat
Promoting Powder Metallurgy Technology

transfer and in order to act as structural support for the plates. Each channel is sandwiched
between two cold side channels and vice versa, except for the external ones.
Benefits:
• Slightly improved performances with a global HTC of 50 [W/m2/°C] than traditional gas-
gas counter-flow heat exchanger (10 and 40 [W/m2/°C])

Italian Institute of Technology IMPROVED

AM PERFORMANCE
and Politecnico di Torino

ROTARY STEERABLE SYSTEM

Material: 17-4PH
Additive process used: Laser Beam Melting

Description: More durable and flexible oilfield drilling equipment made on EOSINT
M280 machine.
Benefits:
• Drilling assembly with part number reduced from four separate components to one
• Optimized design increases drilling accuracy, and reduces post-processing and
production costs
• Shorter lead times and time-to-market

IMPROVED
APS technologies AM PERFORMANCE

6 www.epma.com/spotlightonpm
 Medical

STATOR SEGMENT OF AXIAL

COMPRESSOR
Material: Nickel base 718
Part dimensions (cm): 10 x 5
Additive process used: Laser Beam Melting

Description: Thin and high stator blades are difficult to manufacture because of vibration
issues during milling process and the surface finishing is very challenging and time intensive.
Produced on EOS M 290 and one step post processing with MMP Technology®.

Promoting Powder Metallurgy Technology

Benefits:
• Reduction of production complexity: only two steps
• Easy post processing with MMP
• New designs with more and closer stator blades possible
• Larger Segments reduce installation time and installation complexity on axial compressor

IMPROVED
AM PERFORMANCE

STIRLING REGENERATOR
Material: 316L
Part size (mm): 62 Ф, 43 height
Part weight (g): 400
Additive process used: Laser Beam Melting

Description: Regenerator comprising an interior lattice structure to increase its efficiency.

This lattice structure allows minimised pressure loss derived from the path of the gaseous
working fluid and increases the heat transference.
Benefits:
• Shorter leadtime
• Lattice structures with controlled porosity leading to improved heat transfer
vs. conventional overlapping wire meshes, matrix of laminates, metallic foams or
perforated sheets

IMPROVED
IK4-Lortek and Centro Stirling AM PERFORMANCE

www.epma.com/spotlightonpm 7
 Spotlight on PM

TWISTER USED IN AN AIR

EXTRACTION PUMP
Material: 316L
Part height: 185
Part diameter: 95
Process used: Laser Beam Melting

Description: Twister component used in an air extraction pump of a combined cycle gas
turbine plant condenser to create a swirl in the water flow. After an internal qualification
program, the twister was successfully put into service in October 2016 and removed
Promoting Powder Metallurgy Technology

after 2000 hours in operation. Non-destructive evaluation did not reveal any cracking or
critical degradation.
Benefits:
• Shorter leadtime and cheaper than conventional casting
• Suitable for on-demand manufacturing of spare or obsolete parts, with comparable costs
vs. 5-axis CNC machining

COST
ENGIE Laborelec AM SAVING

COMPOUND RAISER PIPE

FOR OIL REFINERY
CRACKING PLANT
Material: High-temperature erosion-resistant metal
matrix composite Ralloy DMMC 20 internal cladding
Thickness of coating (mm): 18
Pipe diameters (mm): OD 625-650, ID 510
Process used: Laser Beam Melting
Benefits:
• Improved erosion resistance vs. Weld cladding
• Longer lifetime (from 2-3 months to 3-5 years)
• Resistance to high temperature over 600°C
• Resistance to high catalyst flow rate (~ 40 m/s)
• Reduced weld repair frequency and shutdowns

IMPROVED
HIP PERFORMANCE

8 www.epma.com/spotlightonpm
 Medical

IMPELLER FOR GAS

COMPRESSOR
Masterial: Nickel-base alloy (Ni 625)
Part dimensions (diameter) (mm): up to 1000
Benefits:
• New net shape design possibilities
• Machining, brazing and welds avoided
• Cost savings
• More advanced materials can be used
•

Promoting Powder Metallurgy Technology

Less inspection

Synertech HIP COST

SAVING

MANIFOLD FOR TOPSIDE

AND SUBSEA STATIONS
Material: Duplex stainless steel UNS31803, UNS32760
and Super duplex
Part weight (tonnes): 1 to 4
Part dimensions (mm): Internal diameter 400
Benefits:
• Less welds: design with integrated branches
• Less NDE
• Less machining
• Optimized wall thickness
• Clad design also possible

IMPROVED
HIP PERFORMANCE

www.epma.com/spotlightonpm 9
 Spotlight on PM

NNS REACTOR COOLANT

PUMP IMPELLER
Product Density (g/cm3): 7.96
Tensile Strength (MPa): 580
Yield Strength (MPa): 290
Product Hardness (HRB): 220 HV
Elongation (%): 57
Benefits:
• Extended component lifetime
•
Promoting Powder Metallurgy Technology

Excellent mechanical properties on a large scale component

IMPROVED
HIP PERFORMANCE

ROTOR FOR STEAM AND GAS

TURBINE
Material: 12%Cr steel
Part weight (tonnes): up to 10
Benefits:
• Shorter leadtime
• Dual material capability

HIP IMPROVED
PERFORMANCE

10 www.epma.com/spotlightonpm
 Medical

SWIVEL FOR OFFSHORE

INDUSTRY
Material: Stainless steel
Part weight (tonnes): 9
Benefits:
• Complex internal cooling channels
• Weight reduction

Promoting Powder Metallurgy Technology

WEIGHT
HIP SAVING

VALVE BODY FOR OFFSHORE

SUBSEA STATIONS
Material: Duplex stainless steel UNS31803, UNS32760
and Super duplex and UNS31254, Ni 625 etc
Part weight: 250 kg to 2 tonnes
Benefits:
• Improved strength properties vs. cast materials
• Easy inspection (reliable inspection by ultrasonic)
• No weld
• Less machining
• Optimized wall thickness
• Clad design also possible
• No need for repair welding
• Fast and reliable manufacturing route

IMPROVED
HIP PERFORMANCE

www.epma.com/spotlightonpm 11
 Spotlight on PM

WYE-PIECE FOR OFFSHORE

SUBSEA STATION
Material: Duplex stainless steel UNS S318 03
Part weight (tonnes): 2
Benefits:
• More freedom in design
• 40% weight reduction vs cast/forged parts to withstand
the 250 bar design pressure
• Optimized wall thickness
Promoting Powder Metallurgy Technology

WEIGHT
HIP SAVING

Contributing Companies
APS technologies IK4-Lortek
Aubert & Duval Italian Institute of Technology
Centro Stirling Politecnico di Torino
ENGIE Laborelec Metso
EOS GmbH Sandvik
Erasteel Siemens Industrial Turbomachinery AB
Euro-K Synertech
Framatome
The EPMA website www.epma.com is a world leading source of PM information.
The EPMA Members online directory is an easy-to-use searchable database that
provides detailed company profiles, product listings and contact details.

www.epma.com/spotlightonpm

12 www.epma.com/spotlightonpm
 european powder
Promoting Powder Metallurgy Technology metallurgy association

For more information on

Powder Metallurgy

For more information on the European Additive

Manufacturing Group (EuroAM) visit www.epma.com/am

For more information on the European Functional

Materials Group (EuroFM) visit www.epma.com/fm

For more information on the European Hard Materials

Group (EuroHM) visit www.epma.com/hm

For more information on the European Hot Isostatic

Pressing Group (EuroHIP) visit www.epma.com/hip

For more information on the European Metal Injection

Moulding Group (EuroMIM) visit www.epma.com/mim

For more information on the European Press & Sinter

Group (EuroPress&Sinter) visit www.epma.com/press-sinter
Representing the Powder Metallurgy Industry european powder
metallurgy association

EPMA Membership Benefits

10 Reasons to join the EPMA
Enhance your market knowledge through access to unique industry information
1 using our range of powder metal PM statistics, presentations and papers.

Improve your product development through access to EU and EPMA Member

2 initiated R&D programmes.

Save money by receiving substantial discounts on attending and exhibiting at the

3 leading annual Euro PM Congress and Exhibition and our series of training courses.

Obtain unique international access to government via our lobbying of the EU on

4 key issues such as REACH, ISO standards and health and safety legislation.

Promote your sales through free advertising via an entry in the EPMA Members
5 Directory on one of the world’s most visited PM websites.

Keep updated on industry news and developments through the Email News service,
6 journal ‘Powder Metallurgy’ and the EPMA newsletter – all free to EPMA Members*.

Develop your high-level networking opportunities through EPMA Sectoral Groups,

7 training seminars and the general assembly.

Keep compliant with ISO 9001:2000 and ISO/TS 16949:2002 by participating in

8 the EPMA Europe-Wide Benchmarking programme.

Access Member only content from a range of sources via the EPMA website
9 Members Area.

Develop the market for your products by supporting promotion of PM technology

10 via exhibitions and web-based information.

www.epma.com/membership
*Student members do not receive the journal Powder Metallurgy as part of their membership
 european powder
Developing the Powder Metallurgy Future metallurgy association

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Maastricht, The Netherlands

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