GKN : Powder Metallurgy awarded for design excellence

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GKN Sinter Metals received three prestigious design awards from the Metal Powder Industries Federation (MPIF) at the annual technical conference POWDERMET2016. This annual awards competition, held in Boston and sponsored by MPIF, sees parts makers from MPIF's member companies invited to submit components that demonstrate the benefits of Powder Metallurgy technology.

Submission were reviewed by a panel of judges with criteria based on design configuration (40%), engineering properties (40%) and promotional value (20%). GKN was awarded for the following technologies: Forged Powder Metal (FPM) Differential Gear Set, Aluminum Heat Sink, and Electric Power Steering Pulley.

1. The Grand Prize in the Automotive-Transmission Category was awarded to GKN Sinter Metals for the Differential Gear Set, which includes five components-a side gear, two pinion gears, a locking side gear, and a locking plate-comprising a forged PM electronic locking differential gear set made for Ford Motor Co. The parts go into the rear axle differential of the Ford F-150 light truck; the first time forged powder metal differential gears have been used in such an application. The higher performance delivered by the forged PM differential gears compared to that of competing metal-forming processes will help usher in downsized gear systems, satisfying a critical need in future automotive design.

2. GKN was also recognized for an Award of Distinction in the Electronic/Electrical Category for an Aluminum PM Heat Sink made for Visteon. The part is used in a high-volume global automotive stereo application. The part is produced to net shape with no secondary machining operations needed. The high material ductility of the special aluminum PM alloy, combined with the precise positioning of the tooled-in assembly holes, enables assembly of the heat sink without the need for attachment screws.

3. Another Award of Distinction was given to GKN Sinter Metals in the Automotive-Chassis Category for a copper-steel driven pulley for an Electric Power Steering System made for Nexteer Automotive. The pulley is a complex net-shape-compacted part with a unique helical geometry and tight tolerances. Close collaboration with the customer in the design of the part, which includes net-formed lightening holes, yielded savings of more than 10%.

GKN's VP of Lightweight Technology, Alan Taylor, played a major role in organising this year's submissions. He said 'MPIF is a well-known industry trade group who awards the best designers in the industry. Since GKN has such a broad range of products it made our choices quite simple. Of the three parts that were submitted, one was Powder Forging, the other Aluminum Powder Metallurgy and lastly, Conventional PM. All three have performance and light weighting attributes to help boost fuel economy. It was truly an honour for us to be recognisedfor all three of our submitted parts.'