Top Ten Companies in Powder Metallurgy

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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.

INTENDED AUDIENCE

This report is intended especially for customers and suppliers of powder metal technologies and products, and others with a need to understand the status and dynamics of the market for these products. This report is largely nontechnical in nature and coverage. It is concerned less with theory and jargon than with what works, who the major global players are, what technological trends are seen in the market place and which intellectual properties and regulations are shaping the market.As such, the report's content should be highly useful to executive management personnel and marketing and financial analysts due to the organized presentation of data. It is not written specifically for scientists and technologists, although its findings concern the market for their work, which should interest them and provide them with a clearer perspective as to how their work can influence the future of the industry. Since this is a vast field, there are a multitude of established research organizations and universities as well as industrial organizations and associations active in this area; these details are briefly covered in this report.

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.

REPORT HIGHLIGHTS

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.

STUDY GOAL AND OBJECTIVES 1

INTENDED AUDIENCE 2

SCOPE 2

ABOUT THE AUTHOR 2

RELATED BCC REPORTS 2

BCC ONLINE SERVICES 3

DISCLAIMER 3

CHAPTER 2 OVERVIEW OF THE POWDER METAL MARKET 5METAL POWDER MANUFACTURERS 5PM COMPONENT FABRICATORS 5NATURE, SIZE AND IMPACT OF PM INDUSTRY 6TABLE 1 NUMBER OF PM COMPANIES AND ORGANIZATIONS BY COUNTRY 7TABLE 2 METAL POWDER INDUSTRY GROUPS AND MEMBERSHIP COUNT 8TABLE 3 WEBSITES OF PM INDUSTRY GROUPS 9

CHAPTER 3 THE PM GLOBAL MARKET AND MAJOR PLAYERS 11

TABLE 4 TOP 10 COMPANIES IN PM INDUSTRY ($ MILLIONS) 11

TABLE 5 UP-AND-COMING GLOBAL PLAYERS IN THE PM INDUSTRY 12

TABLE 6 SELECTED PM COMPANIES IN CHINA 13

TABLE 7 SELECTED PM COMPANIES IN INDIA 14

TABLE 8 SELECTED PM COMPANIES IN JAPAN 14

TABLE 9 SELECTED PM COMPANIES IN KOREA 15

TABLE 10 SELECTED PM COMPANIES IN TAIWAN 15

CHAPTER 4 THE TOP 10 COMPANIES IN THE PM INDUSTRY 17BASF 17COMPANY INFORMATION 17POWDER METALLURGY PRODUCTS AND TECHNOLOGIES 17MEMBERS OF SUPERVISORY BOARD 19BOARD OF EXECUTIVE DIRECTORS 19FINANCIALS 19TABLE 11 BASF CHEMICALS FINANCIALS AND SEGMENT REVENUE SHARES, 2008–2011 (€MILLIONS) 20TABLE 12 BASF INORGANIC SUBSEGMENT REVENUES BY REGION, 2008–2011 (%) 20TABLE 13 U.S. PATENTS ASSIGNED TO BASF IN POWDER METALLURGY-RELATEDTECHNOLOGY SINCE 1976 20CARPENTER TECHNOLOGY CORP. 21COMPANY INFORMATION 21HISTORY OF THE COMPANY 23SUBSIDIARY LIST 24COMPANY LOCATIONS 24PRODUCTS LIST 25POWDER PRODUCTS AND APPLICATIONS 25STRATEGIC PARTNERSHIP 26BOARD OF DIRECTORS 27MANAGEMENT TEAM 27FINANCIALS 28TABLE 14 CARPENTER TECHNOLOGY COMPANY FINANCIALS, 2008–2012 ($ MILLIONS) 28TABLE 15 CARPENTER TECHNOLOGY COMPANY REVENUES BY MARKET, 2010–2012 ($MILLIONS) 28TABLE 16 CARPENTER TECHNOLOGY COMPANY REVENUES BY MATERIAL TYPE, 2010–2012($ MILLIONS) 29TABLE 17 CARPENTER TECHNOLOGY SEGMENT FINANCIALS, 2010-2012 ($ MILLIONS) 29TABLE 18 U.S. PATENTS ASSIGNED TO CARPENTER TECHNOLOGIES SINCE 1976 29FUKUDA METAL FOIL AND POWDER CO. 31COMPANY INFORMATION 31PROCESS CAPABILITIES: POWDERS 32APPLICATION MARKETS AND INDUSTRIES : POWDERS 33COMPANY HISTORY 33FINANCIALS 37TABLE 19 FUKUDA COMPANYWIDE FINANCIALS, 2008–2011 (¥ MILLIONS) 37TABLE 20 U.S. PATENTS ASSIGNED TO FUKUDA METAL FOIL AND POWDER COMPANYSINCE 1976 37GKN PLC 38COMPANY INFORMATION 39COMPANY LOCATIONS: HOEGANAES 40COMPANY LOCATIONS: GKN SINTER METALS 40COMPANY LOCATIONS: GKN SINTER METALS SALES OFFICES 40COMPANY HISTORY 41MANAGEMENT: BOARD OF DIRECTORS 41FINANCIALS 42TABLE 21 GKN POWDER METALLURGY DIVISION FINANCIALS, 2007–2011 (GBPMILLIONS/%/NO.) 42TABLE 22 GKN POWDER METALLURGY DIVISION SALES BY SEGMENT AND REGION, 2010AND 2011 (GBP MILLIONS) 42TABLE 23 GKN POWDER METALLURGY REVENUE BY CUSTOMER, 2010 AND 2011 (% OFTOTAL REVENUES) 42TABLE 24 U.S. PATENTS ASSIGNED TO GKN PM DIVISION SINCE 1976 43H.C. STARCK 46COMPANY INFORMATION 46H.C. STARCK LOCATIONS AND ORGANIZATION 47MANAGEMENT: EXECUTIVE BOARD 47MANAGEMENT: SUPERVISORY BOARD 47FINANCIALS 48TABLE 25 H.C. STARCK COMPANY FINANCIALS FROM BAYER REPORTS, 2002–2006 (€MILLIONS) 48TABLE 26 H.C. STARCK COMPANY FINANCIALS RECENT YEARS, 2009–2011 (€ MILLIONS) 49TABLE 27 H.C. STARCK BALANCE SHEET FROM BAYER REPORTS, 2006 (€ MILLIONS) 49TABLE 28 H.C. STARCK: NUMBER OF EMPLOYEES BY LOCATION, 2011 50TABLE 29 U.S. PATENTS ASSIGNED TO H.C. STARCK SINCE 1976 50HITACHI POWDER METALS CO. LTD. 56COMPANY INFORMATION 56COMPANY LOCATIONS 58SUBSIDIARIES AND AFFILIATES 58COMPANY HISTORY 58PRODUCTS AND DESCRIPTIONS 59BOARD OF DIRECTORS 60EXECUTIVE OFFICERS 61FINANCIALS 61TABLE 30 HITACHI CHEMICALS COMPANY FINANCIALS, 2006–2011 (¥ BILLIONS) 62TABLE 31 HITACHI METAL POWDER FINANCIALS PRIOR TO MERGER WITH HITACHICHEMICALS, 2005–2007 (¥ MILLIONS) 62TABLE 32 HITACHI CHEMICALS FINANCIALS FOR THE SEGMENT INCLUDING METALPOWDER BUSINESS, 2008–2011 (¥ BILLIONS) 63TABLE 33 U.S. PATENTS ASSIGNED TO HITACHI PM SINCE 1976 63HOGANAS AB 66COMPANY INFORMATION 66COMPANY SUBSIDIARIES 67COMPANY HISTORY 68MANAGEMENT 69BOARD OF DIRECTORS 69FINANCIALS 70TABLE 34 HOGANAS COMPANY FINANCIALS, 2007-2011 (SEK MILLIONS) 70TABLE 35 HOGANAS COMPANY SALES BY REGION, 2008-2011 (SEK MILLIONS) 70TABLE 36 HOGANAS COMPANY SALES BY REPORTING SEGMENTS, 2008-2011 (%) 70TABLE 37 HOGANAS COMPANY'S AVERAGE NUMBER OF EMPLOYEES BY COUNTRY, 2011 71TABLE 38 U.S. PATENTS ASSIGNED TO HOGANAS AB SINCE 1976 (SEK MILLIONS) 71METALDYNE LLC 74COMPANY INFORMATION 74COMPANY AND OWNERSHIP HISTORY 75Founding and Early History into the 1940s 75Masco in the 1950s, 1960s and 1970s 75Reorganizing in the 1980s and 1990s 76Metaldyne History 76Asahi Ownership 76Bankruptcy 76Post Bankruptcy to Late 2012 77COMPANY LOCATIONS 77MANAGEMENT: METALDYNE 78FINANCIALS 78TABLE 39 METALDYNE FINANCIALS REPORTED THROUGH ASAHI TEC, 2006-2008 (Â¥MILLIONS) 79TABLE 40 METALDYNE FINANCIALS BEFORE ASAHI ACQUISITION, 2004 AND 2005 (¥MILLIONS) 79TABLE 41 U.S. PATENTS ASSIGNED TO MASCOTECH SINCE 1976 79TABLE 42 U.S. PATENTS ASSIGNED TO METALDYNE SINCE 1976 81TABLE 43 U.S. PATENTS ASSIGNED TO ASAHI TEC SINCE 1976 82MIBA AG 82COMPANY INFORMATION 83COMPANY HISTORY 83COMPANY LOCATIONS 84MANAGEMENT BOARD 85FINANCIALS 86TABLE 44 MIBA AG COMPANY FINANCIALS, 2008â??2011 (& EURO; MILLIONS) 86TABLE 45 MIBA AG COMPANY REVENUE SHARES BY SEGMENT AND GEOGRAPHIC REGION,2009–2011 (%) 86TABLE 46 MIBA AG EMPLOYEE COUNT BY COUNTRY AND DIVISION, 2009–2011 87TABLE 47 U.S. PATENTS ASSIGNED TO MIBA AG SINCE 1976 87RIO-TINTO 89COMPANY INFORMATION 90HISTORY OF QIT AND QUEBEC METAL POWDERS 90PRODUCTS AND APPLICATIONS 91H2OMET TECHNOLOGY: A NEW APPLICATION 91MANAGEMENT 92FINANCIALS 92TABLE 48 RIO TINTO DIAMONDS AND MINERALS DIVISION FINANCIALS, 2009–2011 ($MILLIONS) 93TABLE 49 RIO TINTO'S SHARE OF MINERAL RESERVES AND PRODUCTION VOLUMES(MILLIONS OF TONNES) 93TABLE 50 RIO TINTOS: NUMBER OF EMPLOYEES WITHIN DIAMONDS AND MINERALSDIVISION, 2009–2011 94TABLE 51 U.S. PATENTS ASSIGNED TO RIO TINTO (QMP) SINCE 1976 94

TABLE 2 METAL POWDER INDUSTRY GROUPS AND MEMBERSHIP COUNT 8

TABLE 3 WEBSITES OF PM INDUSTRY GROUPS 9

TABLE 4 TOP 10 COMPANIES IN PM INDUSTRY ($ MILLIONS) 11

TABLE 5 UP-AND-COMING GLOBAL PLAYERS IN THE PM INDUSTRY 12

TABLE 6 SELECTED PM COMPANIES IN CHINA 13

TABLE 7 SELECTED PM COMPANIES IN INDIA 14

TABLE 8 SELECTED PM COMPANIES IN JAPAN 14

TABLE 9 SELECTED PM COMPANIES IN KOREA 15

TABLE 10 SELECTED PM COMPANIES IN TAIWAN 15

TABLE 11 BASF CHEMICALS FINANCIALS AND SEGMENT REVENUE SHARES, 2008–2011 (€

MILLIONS) 20

TABLE 12 BASF INORGANIC SUBSEGMENT REVENUES BY REGION, 2008–2011 (%) 20

TABLE 13 U.S. PATENTS ASSIGNED TO BASF IN POWDER METALLURGY-RELATED

TECHNOLOGY SINCE 1976 20

TABLE 14 CARPENTER TECHNOLOGY COMPANY FINANCIALS, 2008–2012 ($ MILLIONS) 28

TABLE 15 CARPENTER TECHNOLOGY COMPANY REVENUES BY MARKET, 2010–2012 ($

MILLIONS) 28

TABLE 16 CARPENTER TECHNOLOGY COMPANY REVENUES BY MATERIAL TYPE, 2010–2012

($ MILLIONS) 29

TABLE 17 CARPENTER TECHNOLOGY SEGMENT FINANCIALS, 2010-2012 ($ MILLIONS) 29

TABLE 18 U.S. PATENTS ASSIGNED TO CARPENTER TECHNOLOGIES SINCE 1976 29

TABLE 19 FUKUDA COMPANYWIDE FINANCIALS, 2008–2011 (¥ MILLIONS) 37

TABLE 20 U.S. PATENTS ASSIGNED TO FUKUDA METAL FOIL AND POWDER COMPANY SINCE

1976 37

TABLE 21 GKN POWDER METALLURGY DIVISION FINANCIALS, 2007–2011 (GBP

MILLIONS/%/NO.) 42

TABLE 22 GKN POWDER METALLURGY DIVISION SALES BY SEGMENT AND REGION, 2010

AND 2011 (GBP MILLIONS) 42

TABLE 23 GKN POWDER METALLURGY REVENUE BY CUSTOMER, 2010 AND 2011 (% OF

TOTAL REVENUES) 42

TABLE 24 U.S. PATENTS ASSIGNED TO GKN PM DIVISION SINCE 1976 43

TABLE 25 H.C. STARCK COMPANY FINANCIALS FROM BAYER REPORTS, 2002–2006 (€

MILLIONS) 48

TABLE 26 H.C. STARCK COMPANY FINANCIALS RECENT YEARS, 2009–2011 (€ MILLIONS) 49

TABLE 27 H.C. STARCK BALANCE SHEET FROM BAYER REPORTS, 2006 (€ MILLIONS) 49

TABLE 28 H.C. STARCK: NUMBER OF EMPLOYEES BY LOCATION, 2011 50

TABLE 29 U.S. PATENTS ASSIGNED TO H.C. STARCK SINCE 1976 50

TABLE 30 HITACHI CHEMICALS COMPANY FINANCIALS, 2006–2011 (¥ BILLIONS) 62

TABLE 31 HITACHI METAL POWDER FINANCIALS PRIOR TO MERGER WITH HITACHI

CHEMICALS, 2005–2007 (¥ MILLIONS) 62

TABLE 32 HITACHI CHEMICALS FINANCIALS FOR THE SEGMENT INCLUDING METAL

POWDER BUSINESS, 2008–2011 (¥ BILLIONS) 63

TABLE 33 U.S. PATENTS ASSIGNED TO HITACHI PM SINCE 1976 63

TABLE 34 HOGANAS COMPANY FINANCIALS, 2007-2011 (SEK MILLIONS) 70

TABLE 35 HOGANAS COMPANY SALES BY REGION, 2008-2011 (SEK MILLIONS) 70

TABLE 36 HOGANAS COMPANY SALES BY REPORTING SEGMENTS, 2008-2011 (%) 70

TABLE 37 HOGANAS COMPANY'S AVERAGE NUMBER OF EMPLOYEES BY COUNTRY, 2011 71

TABLE 38 U.S. PATENTS ASSIGNED TO HOGANAS AB SINCE 1976 (SEK MILLIONS) 71

AVM088A - Top Ten Companies in Powder Metallurgy

Copyright © BCC Research, Wellesley MA USA, Website: www.bccresearch.com

TABLE HEADING PAGE NO.

TABLE 39 METALDYNE FINANCIALS REPORTED THROUGH ASAHI TEC, 2006-2008 (Â¥

MILLIONS) 79

TABLE 40 METALDYNE FINANCIALS BEFORE ASAHI ACQUISITION, 2004 AND 2005 (¥

MILLIONS) 79

TABLE 41 U.S. PATENTS ASSIGNED TO MASCOTECH SINCE 1976 79

TABLE 42 U.S. PATENTS ASSIGNED TO METALDYNE SINCE 1976 81

TABLE 43 U.S. PATENTS ASSIGNED TO ASAHI TEC SINCE 1976 82

TABLE 44 MIBA AG COMPANY FINANCIALS, 2008â??2011 (& EURO; MILLIONS) 86

TABLE 45 MIBA AG COMPANY REVENUE SHARES BY SEGMENT AND GEOGRAPHIC REGION,

2009–2011 (%) 86

TABLE 46 MIBA AG EMPLOYEE COUNT BY COUNTRY AND DIVISION, 2009–2011 87

TABLE 47 U.S. PATENTS ASSIGNED TO MIBA AG SINCE 1976 87

TABLE 48 RIO TINTO DIAMONDS AND MINERALS DIVISION FINANCIALS, 2009–2011 ($

MILLIONS) 93

TABLE 49 RIO TINTO'S SHARE OF MINERAL RESERVES AND PRODUCTION VOLUMES

(MILLIONS OF TONNES) 93

TABLE 50 RIO TINTOS: NUMBER OF EMPLOYEES WITHIN DIAMONDS AND MINERALS

DIVISION, 2009–2011 94

TABLE 51 U.S. PATENTS ASSIGNED TO RIO TINTO (QMP) SINCE 1976 94

To order this report:Metal_Manufacturing Industry: Top Ten Companies in Powder Metallurgy

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