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PM research: Inventing the future
PM
VIEWPOINT
PM research: Inventing the future I
f t h e r e c e n t g r o w t h in t h e n u m b e r of p a p e r s s u b m i t t e d to p o w d e r m e t a l l u r g y (PM) conferences is a n y guide, PM r e s e a r c h is enjoying a h e a l t h y boom. Does t h i s upsurge foretell a new burst of g r o w t h in t h e PM i n d u s t r i e s ? To e x a m i n e t h i s q u e s t i o n m o r e closely, it is w o r t h looking a t t h e c u r r e n t focus of PM research. F o r t u n a t e l y , research and technological progress in N o r t h America, E u r o p e , a n d J a p a n were reviewed by l e a d i n g e x p e r t s in t h o s e regions in a series of p a p e r s p u b l i s h e d e a r l i e r t h i s y e a r in t h e
International Journal of Powder Metallurgy. Before delving into t h e o p i n i o n s of t h o s e a u t h o r s , it is w o r t h t a k i n g one l a s t look at t h e 1992 PM World C o n g r e s s for s o m e s t a t i s t i c s . The d i s t r i b u t i o n of p r e s e n t a t i o n t o p i c s s h o u l d give s o m e i d e a of w h e r e PM r e s e a r c h is h e a d e d , b e c a u s e research-type papers are generally p r e s e n t e d at such m e e t i n g s w i t h i n a y e a r or so of c o m p l e t i o n . Setting aside those papers concerned with i n d u s t r y reviews, s t a n d a r d s , etc., classification of t h e r e m a i n d e r by p r o c e s s i n t e r e s t shows t h a t h a l f of t h e m were c o n c e r n e d w i t h ' a d v a n c e d ' processing. Topics such as injection m o u l d i n g , spray-forming, m e c h a n i cal-alloying, PM c o m p o s i t e p r o d u c tion and other novel processing t e c h n i q u e s o u t n u m b e r e d by far t h e coverage of c o n v e n t i o n a l c o m p a c t i o n a n d sintering, etc. Not surprisingly, w h e n a n a l y s e d a c c o r d i n g to t h e type of m a t e r i a l being discussed, ' c o n v e n t i o n a l ' ferrous a n d non-ferrous PM m a t e r i a l s were d e a l t w i t h in j u s t u n d e r 50% of t h e p a p e r s . The b a l a n c e a d d r e s s e d a b e w i l d e r i n g v a r i e t y of a d v a n c e d m a terials. Thus t h e p a p e r s d i s c u s s i n g PM composites, i n t e r m e t a l l i c s , mechanically-alloyed and nano-scale m a t e r i a l s collectively o u t n u m b e r e d t h o s e d e a l i n g with all of t h e ferrous m a t e r i a l s ( p l a i n a n d alloyed steels, s t a i n l e s s a n d tool steels). If t h i s analysis is a r e a s o n a b l e g u i d e to t h e d i r e c t i o n s in w h i c h r e s e a r c h is being p u r s u e d , d o e s t h e 60 MPR December 1992
r e s u l t signify an i m m i n e n t b o o m in a d v a n c e d m a t e r i a l s manufacturing?. Or t h e decline of f e r r o u s PM? Not very likely. W h e n we reflect on t h e p r o g r e s s of o t h e r l e a d i n g - e d g e technologies t h a t were t h e ' h o t t o p i c s ' of e a r l i e r R&D p r o g r a m m e s a n d conference agendas, t h e long d e l a y t i m e for significant c o m m e r c i a l e x p l o i t a t i o n is p e r h a p s one of t h e m o s t striking features. Powder forging c o m e s p a r t i c u l a r l y to m i n d here.
"...the focus of much academic research on PM-related topics is oriented more towards developing interesting materials than solving existing problems." Professor R a n d a l l G e r m a n in his review of c u r r e n t PM r e s e a r c h in t h e USA also p r o v i d e s a few clues to t h e d i s p a r i t y b e t w e e n i n d u s t r i a l activity and the thrust of the research community. He confirms t h e r a p i d i n c r e a s e in t e c h n i c a l activity in PM over t h e l a s t few y e a r s a n d a shift of i n t e r e s t to PM c o m p o s i t e s a n d to finer p o w d e r s -- typically in highp e r f o r m a n c e m a t e r i a l s . At t h e s a m e time, fundamental work on the ( t r a d i t i o n a l ) PM p r o c e s s was being pursued at various universities and t h r o u g h c o l l a b o r a t i v e efforts f u n d e d by g o v e r n m e n t a n d i n d u s t r y a t t h e N a t i o n a l C e n t e r of E x c e l l e n c e in Metalworking Technology and the C e n t e r for PM Technology. Nevertheless, i n c r e m e n t a l i m p r o v e m e n t of traditional materials and other prob l e m s of m a i n s t r e a m c o n v e n t i o n a l p r o d u c t i o n a t t r a c t e d little a t t e n t i o n from t h e ( a c a d e m i c ) r e s e a r c h community. Professor G e r m a n c o n c l u d e s t h a t " t h e f u t u r e in t h e USA will be for m o r e infusion of t e c h n o l o g y into t h e b a s i c PM o p e r a t i o n s , largely to better control the final product
a t t r i b u t e s a n d to i m p r o v e p r o d u c t quality". In t h e s a m e issue, Professor J o h n Wood a n d P e t e r Brewin reviewed R&D a n d t h e PM i n d u s t r y in t h e UK, c o n c l u d i n g t h a t "While R&D on p o w d e r s a n d r e l a t e d t e c h n o l o g i e s was e x t r e m e l y b u o y a n t in t h e UK, it r e m a i n e d to be seen w h e t h e r t h e UK industry could benefit from this investment." In J a p a n , r e s e a r c h on new m a t e r i a l s h a s b e e n s t i m u l a t e d for a n u m b e r of y e a r s by MITI u n d e r t h e p r o j e c t for t h e d e v e l o p m e n t of b a s i c t e c h n o l o g y for f u t u r e i n d u s tries. The J a p a n e s e were early to recognize t h a t t h e l o n g - t e r m n a t u r e of such d e v e l o p m e n t s m a d e t h e m too risky for p r i v a t e i n d u s t r y to u n d e r take unaided. Because of t h e a b i l i t y to p r o c e s s c e r t a i n a d v a n c e d m a t e r i a l s by powd e r - m e t a l l u r g i c a l techniques, PM h a s b e c o m e s w e p t u p in t h e i n t e r n a t i o n a l race to a c q u i r e a d v a n c e d m a t e r i a l s technology. Thus t h e focus of m u c h a c a d e m i c r e s e a r c h on P M - r e l a t e d t o p i c s is o r i e n t e d m o r e t o w a r d s t h e d e v e l o p m e n t of i n t e r e s t i n g n e w m a t e r i a l s t h a n solving t h e p r o b l e m s of t h e e x i s t i n g PM industry. Because b a s i c r e s e a r c h o r t e c h n o l o g y development represents only a small fraction of t h e e v e n t u a l c o s t a n d effort in b r i n g i n g a significant n e w t e c h n o l o g y to m a r k e t , w o r r i e s a b o u t t h e 'relevancy' of a c a d e m i c r e s e a r c h seem somewhat misplaced. For the s a m e reasons, t h e c u r r e n t u p s u r g e in PM-related r e s e a r c h a t t h e a c a d e m i c level is unlikely to r e s u l t in r a p i d commercialization. Likewise, the n e a r - t e r m f u t u r e o f e x i s t i n g PM i n d u s t r i e s is m o r e s t r o n g l y tied to political and economic developments. A c a d e m i c r e s e a r c h e r s s h o u l d feel free to l e a v e t h e t i n k e r i n g w i t h e s t a b l i s h e d t e c h n o l o g y to t h e p r a c t i t i o n e r s who a r e b e s t a t it anyway, a n d use t h e i r u n r e s t r i c t e d f u n d i n g to 'go for b r o k e ' on discovering new materials and technologies that could benefit t h e f u t u r e w i t h o u t t h e e x p e c t a t i o n of s h o r t - t e r m returns.
Joseph M. Capus
VIEWPOINT
PM research: Inventing the future I
f t h e r e c e n t g r o w t h in t h e n u m b e r of p a p e r s s u b m i t t e d to p o w d e r m e t a l l u r g y (PM) conferences is a n y guide, PM r e s e a r c h is enjoying a h e a l t h y boom. Does t h i s upsurge foretell a new burst of g r o w t h in t h e PM i n d u s t r i e s ? To e x a m i n e t h i s q u e s t i o n m o r e closely, it is w o r t h looking a t t h e c u r r e n t focus of PM research. F o r t u n a t e l y , research and technological progress in N o r t h America, E u r o p e , a n d J a p a n were reviewed by l e a d i n g e x p e r t s in t h o s e regions in a series of p a p e r s p u b l i s h e d e a r l i e r t h i s y e a r in t h e
International Journal of Powder Metallurgy. Before delving into t h e o p i n i o n s of t h o s e a u t h o r s , it is w o r t h t a k i n g one l a s t look at t h e 1992 PM World C o n g r e s s for s o m e s t a t i s t i c s . The d i s t r i b u t i o n of p r e s e n t a t i o n t o p i c s s h o u l d give s o m e i d e a of w h e r e PM r e s e a r c h is h e a d e d , b e c a u s e research-type papers are generally p r e s e n t e d at such m e e t i n g s w i t h i n a y e a r or so of c o m p l e t i o n . Setting aside those papers concerned with i n d u s t r y reviews, s t a n d a r d s , etc., classification of t h e r e m a i n d e r by p r o c e s s i n t e r e s t shows t h a t h a l f of t h e m were c o n c e r n e d w i t h ' a d v a n c e d ' processing. Topics such as injection m o u l d i n g , spray-forming, m e c h a n i cal-alloying, PM c o m p o s i t e p r o d u c tion and other novel processing t e c h n i q u e s o u t n u m b e r e d by far t h e coverage of c o n v e n t i o n a l c o m p a c t i o n a n d sintering, etc. Not surprisingly, w h e n a n a l y s e d a c c o r d i n g to t h e type of m a t e r i a l being discussed, ' c o n v e n t i o n a l ' ferrous a n d non-ferrous PM m a t e r i a l s were d e a l t w i t h in j u s t u n d e r 50% of t h e p a p e r s . The b a l a n c e a d d r e s s e d a b e w i l d e r i n g v a r i e t y of a d v a n c e d m a terials. Thus t h e p a p e r s d i s c u s s i n g PM composites, i n t e r m e t a l l i c s , mechanically-alloyed and nano-scale m a t e r i a l s collectively o u t n u m b e r e d t h o s e d e a l i n g with all of t h e ferrous m a t e r i a l s ( p l a i n a n d alloyed steels, s t a i n l e s s a n d tool steels). If t h i s analysis is a r e a s o n a b l e g u i d e to t h e d i r e c t i o n s in w h i c h r e s e a r c h is being p u r s u e d , d o e s t h e 60 MPR December 1992
r e s u l t signify an i m m i n e n t b o o m in a d v a n c e d m a t e r i a l s manufacturing?. Or t h e decline of f e r r o u s PM? Not very likely. W h e n we reflect on t h e p r o g r e s s of o t h e r l e a d i n g - e d g e technologies t h a t were t h e ' h o t t o p i c s ' of e a r l i e r R&D p r o g r a m m e s a n d conference agendas, t h e long d e l a y t i m e for significant c o m m e r c i a l e x p l o i t a t i o n is p e r h a p s one of t h e m o s t striking features. Powder forging c o m e s p a r t i c u l a r l y to m i n d here.
"...the focus of much academic research on PM-related topics is oriented more towards developing interesting materials than solving existing problems." Professor R a n d a l l G e r m a n in his review of c u r r e n t PM r e s e a r c h in t h e USA also p r o v i d e s a few clues to t h e d i s p a r i t y b e t w e e n i n d u s t r i a l activity and the thrust of the research community. He confirms t h e r a p i d i n c r e a s e in t e c h n i c a l activity in PM over t h e l a s t few y e a r s a n d a shift of i n t e r e s t to PM c o m p o s i t e s a n d to finer p o w d e r s -- typically in highp e r f o r m a n c e m a t e r i a l s . At t h e s a m e time, fundamental work on the ( t r a d i t i o n a l ) PM p r o c e s s was being pursued at various universities and t h r o u g h c o l l a b o r a t i v e efforts f u n d e d by g o v e r n m e n t a n d i n d u s t r y a t t h e N a t i o n a l C e n t e r of E x c e l l e n c e in Metalworking Technology and the C e n t e r for PM Technology. Nevertheless, i n c r e m e n t a l i m p r o v e m e n t of traditional materials and other prob l e m s of m a i n s t r e a m c o n v e n t i o n a l p r o d u c t i o n a t t r a c t e d little a t t e n t i o n from t h e ( a c a d e m i c ) r e s e a r c h community. Professor G e r m a n c o n c l u d e s t h a t " t h e f u t u r e in t h e USA will be for m o r e infusion of t e c h n o l o g y into t h e b a s i c PM o p e r a t i o n s , largely to better control the final product
a t t r i b u t e s a n d to i m p r o v e p r o d u c t quality". In t h e s a m e issue, Professor J o h n Wood a n d P e t e r Brewin reviewed R&D a n d t h e PM i n d u s t r y in t h e UK, c o n c l u d i n g t h a t "While R&D on p o w d e r s a n d r e l a t e d t e c h n o l o g i e s was e x t r e m e l y b u o y a n t in t h e UK, it r e m a i n e d to be seen w h e t h e r t h e UK industry could benefit from this investment." In J a p a n , r e s e a r c h on new m a t e r i a l s h a s b e e n s t i m u l a t e d for a n u m b e r of y e a r s by MITI u n d e r t h e p r o j e c t for t h e d e v e l o p m e n t of b a s i c t e c h n o l o g y for f u t u r e i n d u s tries. The J a p a n e s e were early to recognize t h a t t h e l o n g - t e r m n a t u r e of such d e v e l o p m e n t s m a d e t h e m too risky for p r i v a t e i n d u s t r y to u n d e r take unaided. Because of t h e a b i l i t y to p r o c e s s c e r t a i n a d v a n c e d m a t e r i a l s by powd e r - m e t a l l u r g i c a l techniques, PM h a s b e c o m e s w e p t u p in t h e i n t e r n a t i o n a l race to a c q u i r e a d v a n c e d m a t e r i a l s technology. Thus t h e focus of m u c h a c a d e m i c r e s e a r c h on P M - r e l a t e d t o p i c s is o r i e n t e d m o r e t o w a r d s t h e d e v e l o p m e n t of i n t e r e s t i n g n e w m a t e r i a l s t h a n solving t h e p r o b l e m s of t h e e x i s t i n g PM industry. Because b a s i c r e s e a r c h o r t e c h n o l o g y development represents only a small fraction of t h e e v e n t u a l c o s t a n d effort in b r i n g i n g a significant n e w t e c h n o l o g y to m a r k e t , w o r r i e s a b o u t t h e 'relevancy' of a c a d e m i c r e s e a r c h seem somewhat misplaced. For the s a m e reasons, t h e c u r r e n t u p s u r g e in PM-related r e s e a r c h a t t h e a c a d e m i c level is unlikely to r e s u l t in r a p i d commercialization. Likewise, the n e a r - t e r m f u t u r e o f e x i s t i n g PM i n d u s t r i e s is m o r e s t r o n g l y tied to political and economic developments. A c a d e m i c r e s e a r c h e r s s h o u l d feel free to l e a v e t h e t i n k e r i n g w i t h e s t a b l i s h e d t e c h n o l o g y to t h e p r a c t i t i o n e r s who a r e b e s t a t it anyway, a n d use t h e i r u n r e s t r i c t e d f u n d i n g to 'go for b r o k e ' on discovering new materials and technologies that could benefit t h e f u t u r e w i t h o u t t h e e x p e c t a t i o n of s h o r t - t e r m returns.
Joseph M. Capus