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Top Ten Companies in Powder Metallurgy

This report identifies:

  • This report identifies the top 10 major manufacturers of powder metal and other related materials, such as ceramics and nanopowders, special alloys and metal matrix composites, and companies that make parts and components for automotive products, industrial and tolling equipment, recreation and hobby items, appliances, business machines and other products.
  • It is written with the intent of covering two major segments of the powder metallurgy industry: (1) those companies that manufacture metal powders, and (2) those who use the metal powders to fabricate components.
  • Also included are descriptions of several up-and-coming global players companies that appear to have the potential to become major contributors in the PM market.

INTRODUCTION

Powder metallurgy is the science of fabrication of components with metal powders as their starting materials. This is in contrast to conventional metallurgy, which involves processes such as melting and pouring, casting, drawing, forming, cutting, machining, welding, extrusion, forging and other related processes. In conventional metallurgy, the metal or alloy is always in a continuous physical form, either solid or liquid, and is made into various shapes and articles using the above-mentioned processes. In the case of powder metallurgy, these processes are replaced by new and easier methods by which to process powders, such as blending, compacting and sintering.

One of the major drawbacks of conventional metallurgy is the phase rule, which dictates what ratios of specific elements can coexist in solid or liquid phase together in one continuum. This drawback is completely eliminated when the metal powders are handled through the powder metallurgical process.

The processes in powder metallurgy mimic those in ceramics, in which powders of different oxides are typically blended and then sintered together to form the final product, combining the desired chemistry, shape and characteristics. Several unique materials and shapes are thus possible under this manufacturing route, and the technology is routinely finding newer niche applications for its products.

Powder metallurgy is sometimes referred to as the chipless process, meaning there is nearly zero waste of material. This is due to the absence of machining operations compared to conventional metallurgical methods mentioned earlier. Statistics show that 97% or higher of the input material is retained in the final part. This alone saves the industry huge amounts of money as all conventional metal processing methods result in double-digit waste of material between incoming material and final product.

This focused report profiles the top 10 companies of this industry globally, and provides comments on several transformative changes that are happening in the powder metallurgy industry. The industry as such has a wide range of companies as players including metal powder manufacturers, part manufacturers, equipment manufacturers, end users and several unique supporting suppliers.

The industry is well developed and mature, and has several global communities, groups, associations and similar organizations that support, campaign for, lobby and market the needs and services of the industry. These range from local clusters to international organizations of various sizes and membership counts. Overall, the industry is estimated to have more than 5,000 companies, not to mention the several thousands of less-established upcoming players.

The powder metallurgy industry caters to a wide range of industries including automotive, aerospace, medical and dental. In the recent years there have also been several new applications for powdered metals such as conductive inks, paints and electronics. This report will explore these application areas in detail.

STUDY GOAL AND OBJECTIVES

This document is a specialty report related to the BCC Research report AVM007K Powder Metallurgy: Technologies and Global Markets, authored by Andrew McWilliams. That report provides a global review of the industry with trends, regulatory aspects and other macro-level factors. In that report, numerous companies are listed in brief along with their region of operation and products. The goal of this document is to provide a more in-depth look at the top-tier companies in the industry and to take a closer look at how the products from these companies are addressed in the market, thus providing an explorative financial and technical review to the readers.

The objectives include identifying companies that are considered the leaders and what technologies or management contributions make them leaders. There are certain market drivers and some constraints to both the companies and to the evolving technology they seek to dominate. There is a desire to ascertain whether these companies will be able to meet the continuing demand for their products by proprietary technology, strategy alliances, superior marketing or other sought-after advantages.

Most of the information presented in this report is based on that available from annual reports, various regulatory filings, company website, U.S. Patent and Trademark Office (USPTO) and other public sources, and the author hereby acknowledges the same. Additional information was sourced from industry experts and people with a close understanding of the industry dynamics.

SCOPE

The scope of this report is focused on a select 10 companies in the powder metals industry. This is in many ways a selected due diligence of the key companies and drivers in the PM marketplace. An attempt has been made to include top companies in metal powder manufacturing as well as those companies that use powder metal to fabricate components. Also included are descriptions of several up-and-coming global players companies that appear to have the potential to become major contributors in the PM market.

ABOUT THE AUTHOR

Vijay Subramanian has a PhD in Materials Science and has extensive experience in the field of materials, including an in-depth understanding of metal powders and its applications. He worked for more than a decade in the automotive industry in the U.S. and later in India, and owns multiple U.S. patents in the fields of coatings and friction materials. He has been authoring reports for BCC Research since 2012.

Table of Contents

Top Ten Companies in Powder Metallurgy

Chapter - 1: INTRODUCTION - Complimentary

  • STUDY GOAL AND OBJECTIVES
  • INTENDED AUDIENCE
  • SCOPE
  • ABOUT THE AUTHOR
  • RELATED BCC REPORTS
  • BCC ONLINE SERVICES
  • DISCLAIMER

Chapter - 2: OVERVIEW OF THE POWDER METAL MARKET

  • METAL POWDER MANUFACTURERS
  • PM COMPONENT FABRICATORS
  • NATURE, SIZE AND IMPACT OF PM INDUSTRY

Chapter - 3: THE PM GLOBAL MARKET AND MAJOR PLAYERS

  • Table 4: TOP 10 COMPANIES IN PM INDUSTRY
  • Table 5: UP-AND-COMING GLOBAL PLAYERS IN THE PM INDUSTRY
  • Table 6: SELECTED PM COMPANIES IN CHINA
  • Table 7: SELECTED PM COMPANIES IN INDIA
  • Table 8: SELECTED PM COMPANIES IN JAPAN
  • Table 9: SELECTED PM COMPANIES IN KOREA
  • Table 10: SELECTED PM COMPANIES IN TAIWAN

Chapter - 4: THE TOP 10 COMPANIES IN THE PM INDUSTRY

  • BASF
  • CARPENTER TECHNOLOGY CORP.
  • FUKUDA METAL FOIL AND POWDER CO.
  • GKN PLC
  • H.C. STARCK
  • HITACHI POWDER METALS CO. LTD.
  • HOGANAS AB
  • METALDYNE LLC
  • MIBA AG
  • RIO-TINTO

List of Tables

  • Table 1: NUMBER OF PM COMPANIES AND ORGANIZATIONS BY COUNTRY
  • Table 2: METAL POWDER INDUSTRY GROUPS AND MEMBERSHIP COUNT
  • Table 3: WEBSITES OF PM INDUSTRY GROUPS
  • Table 4: TOP 10 COMPANIES IN PM INDUSTRY
  • Table 5: UP-AND-COMING GLOBAL PLAYERS IN THE PM INDUSTRY
  • Table 6: SELECTED PM COMPANIES IN CHINA
  • Table 7: SELECTED PM COMPANIES IN INDIA
  • Table 8: SELECTED PM COMPANIES IN JAPAN
  • Table 9: SELECTED PM COMPANIES IN KOREA
  • Table 10: SELECTED PM COMPANIES IN TAIWAN
  • Table 11: BASF CHEMICALS FINANCIALS AND SEGMENT REVENUE SHARES, 2008 2011
  • Table 12: BASF INORGANIC SUBSEGMENT REVENUES BY REGION, 2008 2011
  • Table 13: U.S. PATENTS ASSIGNED TO BASF IN POWDER METALLURGY-RELATED TECHNOLOGY SINCE 1976
  • Table 14: CARPENTER TECHNOLOGY COMPANY FINANCIALS, 2008 2012
  • Table 15: CARPENTER TECHNOLOGY COMPANY REVENUES BY MARKET, 2010 2012
  • Table 16: CARPENTER TECHNOLOGY COMPANY REVENUES BY MATERIAL TYPE, 2010 2012
  • Table 17: CARPENTER TECHNOLOGY SEGMENT FINANCIALS, 2010-2012
  • Table 18: U.S. PATENTS ASSIGNED TO CARPENTER TECHNOLOGIES SINCE 1976
  • Table 19: FUKUDA COMPANYWIDE FINANCIALS, 2008 2011
  • Table 20: U.S. PATENTS ASSIGNED TO FUKUDA METAL FOIL AND POWDER COMPANY SINCE 1976
  • Table 21: GKN POWDER METALLURGY DIVISION FINANCIALS, 2007 2011
  • Table 22: GKN POWDER METALLURGY DIVISION SALES BY SEGMENT AND REGION, 2010 AND 2011
  • Table 23: GKN POWDER METALLURGY REVENUE BY CUSTOMER, 2010 AND 2011
  • Table 24: U.S. PATENTS ASSIGNED TO GKN PM DIVISION SINCE 1976
  • Table 25: H.C. STARCK COMPANY FINANCIALS FROM BAYER REPORTS, 2002 2006
  • Table 26: H.C. STARCK COMPANY FINANCIALS RECENT YEARS, 2009 2011
  • Table 27: H.C. STARCK BALANCE SHEET FROM BAYER REPORTS, 2006
  • Table 28: H.C. STARCK: NUMBER OF EMPLOYEES BY LOCATION, 2011
  • Table 29: U.S. PATENTS ASSIGNED TO H.C. STARCK SINCE 1976
  • Table 30: HITACHI CHEMICALS COMPANY FINANCIALS, 2006 2011
  • Table 31: HITACHI METAL POWDER FINANCIALS PRIOR TO MERGER WITH HITACHI CHEMICALS, 2005 2007
  • Table 32: HITACHI CHEMICALS FINANCIALS FOR THE SEGMENT INCLUDING METAL POWDER BUSINESS, 2008 2011
  • Table 33: U.S. PATENTS ASSIGNED TO HITACHI PM SINCE 1976
  • Table 34: HOGANAS COMPANY FINANCIALS, 2007-2011
  • Table 35: HOGANAS COMPANY SALES BY REGION, 2008-2011
  • Table 36: HOGANAS COMPANY SALES BY REPORTING SEGMENTS, 2008-2011
  • Table 37: HOGANAS COMPANY'S AVERAGE NUMBER OF EMPLOYEES BY COUNTRY, 2011
  • Table 38: U.S. PATENTS ASSIGNED TO HOGANAS AB SINCE 1976
  • Table 39: METALDYNE FINANCIALS REPORTED THROUGH ASAHI TEC, 2006-2008
  • Table 40: METALDYNE FINANCIALS BEFORE ASAHI ACQUISITION, 2004 AND 2005
  • Table 41: U.S. PATENTS ASSIGNED TO MASCOTECH SINCE 1976
  • Table 42: U.S. PATENTS ASSIGNED TO METALDYNE SINCE 1976
  • Table 43: U.S. PATENTS ASSIGNED TO ASAHI TEC SINCE 1976
  • Table 44: MIBA AG COMPANY FINANCIALS, 2008 2011
  • Table 45: MIBA AG COMPANY REVENUE SHARES BY SEGMENT AND GEOGRAPHIC REGION, 2009 2011
  • Table 46: MIBA AG EMPLOYEE COUNT BY COUNTRY AND DIVISION, 2009 2011
  • Table 47: U.S. PATENTS ASSIGNED TO MIBA AG SINCE 1976
  • Table 48: RIO TINTO DIAMONDS AND MINERALS DIVISION FINANCIALS, 2009 2011
  • Table 49: RIO TINTO'S SHARE OF MINERAL RESERVES AND PRODUCTION VOLUMES
  • Table 50: RIO TINTOS: NUMBER OF EMPLOYEES WITHIN DIAMONDS AND MINERALS DIVISION, 2009 2011
  • Table 51: U.S. PATENTS ASSIGNED TO RIO TINTO (QMP) SINCE 1976

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