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Tamagawa Bldg., 2-16, Iwamoto-Cho 2-Chome, Chiyoda-Ku, Tokyo 101-0032, Japan

Production in Japan PM Products

Table 1 shows the production volume of PM products item by item. Fig.1 shows the production volume change of Machine Parts and Bearings for the period from 1998 through 2009.

Table 1 Production of PM Products (Calendar Year) (Metric Tons) (Source: METI)

Kind of Products 2007 2008 2009 09/08 (%) Bearings 7,954 7,718 4,885 63.3 Machine Parts 110,673 103,942 69,755 67.1 Friction Materials 788 738 392 53.1 Electric Contacts 92 77 52 67.5 Miscellaneous* 1,652 1,792 956 53.3 Total 121,159 114,267 76,040 66.5

*Including Electric Collectors and Refractory metals, except Magnetic materials and Cemented carbides

Fig.1 Production of Machine Parts and Bearings

April 30, 2010

Thousand ton

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Machine Parts

The production volume was 69,754 ton, 32.9% decrease over the previous year. The decline of the production volume of machine parts was mainly because of the influence of worldwide demand decline of vehicle parts etc. The production volume has gradually recovered because of the world-wide economic policy. But the time when full-scale recover will occur is uncertain. The quarterly trend over the same period of the previous year showed 60.5% decrease for January through March period, 45.4% decrease for April through June period, 23.5% decrease for July through September period and 8.8% increase for October through December period. The production volume showed gradually increment since fourth quarter by the world-wide economic policy. The production amount of 2009, which is not shown in the table, was 89.7 billion yen that was 31.4% decrease over the previous year. The trend of production volume by user industry was as follows. (Table 2)

Table 2 Analysis of Demand for Machine Parts (Calendar Year) (Metric Tons) (Source: METI)

Demands 2007 2008 2009 09/08 (%) For Vehicles 101,387 94,168 65,035 69.1 For Others 9,286 9,774 4,719 48.3

Total 110,673 103,942 69,754 67.1

For your information, we will refer to the following two points respect of the data of sintered parts used for automobiles, the main user, like the last year. 1) Weight (unit consumption) for sintered parts used for one car

According to the figures in 2008, the weight of sintered parts used for one car was 8.0 kg in Japan (8.8 kg in 2007), 19.0 kg in the U.S. (19.5 kg in 2007) and 9.2 kg in Europe (10.3kg in 2007). Compared with Japan and Europe, the unit consumption in the U.S is outstanding. This is mainly because of the downsizing of products and the differences of parts manufacturing method in Japan and Europe to the U.S. But this trend will grow in Japan and Europe in future.

2) Composition of PM machine parts broken down by applied parts of automobile Fig.2 shows the composition rate of production volume of sintered machine parts applied to respective

section of automobile in 2008 based on the demand structure survey by JPMA.

Fig.2 Breakdown of Machine Parts for Automobile (2008)

A: Engine 52.7% (51.6% in 2007) B: Drive Train 23.5% (24.1% in 2007) C: Chassis 13.5% (13.3% in 2007) D: Electrical 4.6% (4.8% in 2007) E: Body 1.3% F: Fuel 0.5% G: Others 4.0%

B

C

DE F G

A

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Bearings

The production volume of Bearings was 4,487 ton. Just like as Machine parts, Bearings was influenced by worldwide demand decline of vehicle parts etc. The quarterly trend over the same period of the previous year was 64.5% decrease for January through March, 49.7% decrease for April through June, and 27.4% decrease for July through September and 6.0% increase for October through December. The production volume showed steep recovery in fourth quarter. The production amount, which is not shown in table, was 10.4 billion yen that was 33.2% decrease over the previous year. The trend of production volume by user industry was as follows (Table 3).

Table 3 Analysis of Demand for Bearings (Calendar Year) (Metric Tons) (Source: METI)

Demands 2007 2008 2009 09/08(%) For Vehicles 4,619 4,535 2,905 64.1 For Others 3,335 3,183 1,982 62.3

Total 7,954 7,718 4,487 58.1

The major part of vehicles was for automobile usage. The production volume was 2,905 ton that was 35.9% decrease over the previous year. The composition rate was 64.7% that was 5.9% increase over the previous year. The production volume for other use was 2,000 ton that was 37.2% decrease over the previous year. This means the consecutive 5 years decrease. According to JPMA statistics, the use for industrial machines was 52.7% decrease over the previous year and the use for electrical machines was 8.3% decrease over the previous year. The use for industrial machine decreased because of the worldwide recession. The use for electric machines showed overall same trend as industrial machines, because of production transfer to overseas, the production amount decreased.

Powder Shipment

Table 4 shows Shipment of Metal Powders. The domestic shipment of stainless steel powder foe PM use was decreasing every year. The domestic shipment of stainless steel powder in 2008 was 3,212 ton that was 0.8% decrease over the previous year. The domestic shipment of powder for MIM was 507 ton in 2006, 523 ton in 2007 and 405 ton in 2008 that means 32.6% decrease over the previous year. The shipment volume in 2009 is not available yet.

Table 4 Shipments of Metal Powders (Calendar Year) (Metric Tons) (Source: JPMA)

Iron Powder 2007 2008 2009 09/08(%) For PM 131,869 126,995 79,699 62.8

For others 62,081 68,910 60,225 87.4 Export 34,674 30,015 19,780 65.9

Total 228,624 225,920 159,704 70.7 Copper Powder 2007 2008 2009 09/08(%) For PM 6,691 6,229 4,218 67.7

For others 1,465 1,388 841 60.6 Export 784 958 670 69.9

Total 8,939 8,575 5,729 66.8

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Japan Powder Metallurgy Association

Members as at the end of March, 2010

Total 69 Companies & 2 Associations Regular Member PM Products 21Companies Metal Powders 15 Companies Equipments 6 Companies Special Member 1 Company Associate Member Domestic 22 Companies Overseas 4 Companies Complimentary Member 2 Associations

Organization of JPMA

[The number of meeting times in 2009]

1) General Assembly was held 2 times. 2) Board meeting was held 1 time. 3) Permanent Board meeting was held 5 times. 4) Committees were held 61 times.

General Assembly

President

Board of Administration Permanent Board of Directors

Secretariat

Selection Committee for Award Prize

Committee for Administration Sub-Committee for General Affairs Sub-Committee for Public Relations

Technical Committee for Sintered Parts Sub-Committee for Sintered Bearings

Technical Committee for Sintered Friction Materials

Technical Committee for Press Machines

Technical Committee for Metal Powders

Committee for Metal Injection Molding

Marketing Committee

Committee for International Standardizations

Committee for Environment

Sub-Committee for Material Characteristics

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Board Members (at the end of March, 2010) President:

Mr. Yutaka Mizuno (President, Fine Sinter Co., Ltd.) Permanent Board Members:

Mr. Yasuyoshi Saegusa (Executive Offcer, Powder Metal Products Division, Sumitomo Electric Industries, Ltd.)

Mr. Yoshiyasu Iino (President, DIAMET Corporation.) Mr. Hiroshi Fujinami (President, Hitachi Powdered Metals Co., Ltd.)

Mr. Isamu Kikuchi (Chairman, Porite Corporation) Mr. Kan Kudo (Senior General Manager, Steel Powder Division, Kobe Steel, Ltd.) Mr. Carl-Gustav Eklund (President, Höganäs Japan K.K.) Board Members: Mr. Junichi Takahashi (Vice-Chief, Mold Alloy group, IWAKI DIECAST Co., Ltd.)

Mr. Masakazu Achikita (General Manager, Advance Materials Division, Sumitomo Metal Mining Co., Ltd.)

Mr. Masaaki Matsumoto (Friction Material Department, General Manager, Tungaloy Corporation)

Mr. Masahiro Saeki (Executive Officer G.M., Friction Materials Div., Tokai Carbon Co., Ltd.) Mr. Keisuke (Representative Director & President, Nippon Kagaku Yakin Co., Ltd.)

Mr. Minoru Nishimura (President, Fukuisinter Co., Ltd.) Mr. Mitsugu Aikawa (Senior Vice President, JFE Steel Corporation.) Mr. Takaki Furui (General Manager, Division Manager

Advanced Functional Metal Powders Dept, Daido Steel Co., Ltd.) Mr. Atsushi Nagano (General Manager, Advanced Fine Materials Business

Unit, Dowa Electronics Materials Co., Ltd.) Mr. Hideaki Fukui (President, Nippon Atomized Metal Powders Corporation) Mr. Yasuhiko Hayashi (President, Fukuda Metal Foil & Powder Co., Ltd.) Mr. Junichirou Tanaka (Executive General Manager of Engineered Metal Powder Division in Engineered Materials Sector,

Mitsui Mining & Smelting Co., Ltd.) Mr. Akira Kawaguchi (General Manager, Tamagawa Machinery Division,

Mitsubishi Materials Techno Corporation) Executive Director: Mr. Kazunori Arai Auditor: Mr. Kazuhide Kikuchi (General Manager, Friction Materials Dept.

Friction Materials Div., Tokai Carbon Co., Ltd.) Mr. Norihisa Anbiru (Sales Manager Business Department, Mitsui Mining & Smelting Co., Ltd.)

JPMA Secretariat Staff Kazunori Arai (Mr.) (Executive Director) Hiroaki Itabashi (Mr.) (Staff) Yusuke Watanuki (Mr.) (Staff) Emi Sasaki (Ms.) (Staff) Mikie Kuwabara (Ms.) (Staff)

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Activities of Committees

The main activities of various committees in 2009 were as follows.

1) Selection Committee for Award Prize *Selection of JPMA Award (Development Prize)

2) Committee for Administration *Planning and operating of the PR meeting “JPMA Awards Special Session” at JSPM Spring Meeting in June

*Publication of the report “Analysis of investigation results of sintered parts demand structure 2008” in June

*Edition of the brochure “2008 JPMA Annual Report (English)” in May

*Edition of the brochure “2008 JPMA Annual Report (Japanese)” in July

*Planning and operating of “the 7th Research Promotion Program”

*Planning and operating of “PM Information Exchange Meeting” among PM related companies

*Planning and operating of “the Technical Information Meeting”

*Planning and operating for the Asian PM Association

*Planning and operating of “the 14th Case Studies on New Products Development Seminar”

*Planning and operating of the “Case Studies on

Improving Production Efficiency Meeting” as the 28th memorial meeting

*Follow-up of the action plan of “the Vision for PM Industry”

*Renewal of the JPMA Website for “English site and Japanese site”

*Planning of PR activity for the PM2012 *Publication of JPMA News “Funmatsu Yakin” (No.355- 360)

3) Technical Committee for Sintered Parts *Discussion of the matter for ISO/TC 119/SC3 and SC5

*Cooperation of “the 7th Research Promotion Program”

*Information Exchange Program with Technical Committee for Metal Powders and Press Machine

*Collaboration of Sub-Committee for Sintered Bearings

*Deliberation of Standardization for Sintered Bearings

*Deliberation of PR activity for Sintered Bearings

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4) Technical Committee for Sintered Friction Materials

*Exchange of Information for REACH *Renewal of the JPMA Website for “Sintered Friction Materials”

5) Technical Committee for Press Machine *Information Exchange Program with Technical Committee for Sintered Parts and Metal Powders

*Update of the JPMA Website for “Proper Method for Using Press Machine”

6) Technical Committee for Metal Powders *Deliberation of the JPMA Website for “Metal Powders”

*Study on "New Evaluation Items for Powder Characteristics"

*Discussion of the matter for ISO/TC 119/SC2 *Pre-testing of Gustavsssson flow method *Introduction of topics about "Metal Powder" by Committee members and exchange of views

* Information Exchange Program with Technical Committee for Sintered Parts and Press Machine

7) Committee for Metal Injection Molding *Planning and operating of “the 8th MIM Lecture Meeting for Users” in October

*Discussion of the standard “MIM Materials

Specifications” (ISO Draft) *Investigation of the Japanese MIM market *Operating on the Standardization of the Materials Property (fatigue, impact and tensile) with MIM Sectional Committee

8) Marketing Committee *Introduction of topics in Committee members’

company by Committee members and exchange of views

*Introduction of "overseas information" by Committee members

*Round-table discussion by subject with Committee members

9) Committee for International Standardizations *Planning to participate in 2009 ISO/TC119 Conference in Denmark

*Discussion of related matters for TC119, SC2, SC3 and SC5

*Discussion of the future GPMD program

10) Committee for Environment *Investigation of 2008 follow-up survey for "Voluntary Action Plan for Environment of PM Industry"

*Discussion of environmental matters for PM industries

*Introduction of Case Study of “CO2 Emissions Reduction” and “Waste Product Reduction”

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Events

- January - 14: Gathering of 2009 New Year Greeting and

Ceremony of Awarding Various Honors in 2008 Participants: 223

- March - 19: The 16th Technological Information Meeting

3 research reports were presented by each winners of the 6th Research Promotion Program. The 4th PM Information Exchange Meeting

Participants: 58 (including non members)

- May - 5: Tour of Committee for Administration

JSAE AUTOMOTIVE ENGINEERING EXPOSITION

20: 2009 JPMA General Assembly The 2009 Working Plans and Budget of JPMA Participants: 66

- June- 3: JPMA Award Special Session at the JSPM

Spring Meeting Presentation: 14, 2008 Award Winners

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- October - 9 : The 8th MIM PR Seminar for End-Users at Osaka

Participants: 94

14: 2009 JPMA Fall Extraordinary General Assembly 27: The 7th Research Promotion Program at the

JSPM Fall Meeting

- November - 19: The 28rd Case Studies of Production Efficiency

Improvement Meeting & the 14th Metal Powder and Equipment PR Meeting

International Communications

- October - 14: The 1st Board Meeting of Asian Powder

Metallurgy Association (APMA) in Japan

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Awards 1) Association Prize

a) Personal Prize (For distinctive merit to PM industry) Mr. Takayoshi Sugiyama

Former Adviser of SUMITOMO ELECTRIC INDUSTRIES, LTD.

b) Development Prize (Abstracts and photos: page 12-18)

2) Prize for Distinguish Service on the Committee Activities

Mr. Takeshi Oba Hitachi Powdered Metals Co., Ltd.

3) Recognition of Superior Employees Recognition of superior employees is a system that recognizes employees who have been engaging in manufacturing products related to powder metallurgy. The system was started in 1995. 2009 prizewinner numbered 16 persons (12 member companies).

4) Encouragement Prize at Research Promotion Program

This program was started in 2003. This program aimed at promotion of research of ferrous PM at universities and research institutes. 14 Research Reports were presented with posters, and 4 Reports were elected for encouragement prize.

Personal Prize (Mr. Takayoshi Sugiyama)

Prize for Distinguish Service on the Committee Activities

(Mr. & Mrs. Takeshi Oba)

Recognition of Superior Employees

Publications

1) The 30th Investigation Collection Results of Sintered Parts Demand Structure Achievements in 2008 were published. In order to seek for the trend in developing sintered parts market in future, we perform it every year. Planning by the Committee for Administration and editing by secretariat (13 pages/Japanese)

2) JPMA Report, 2008 This report is recording the activities of the JPMA

and the present situation of PM industry in Japan. 42 pages for Japanese version, 20 pages for English version Planning by the Committee for Administration and editing by secretariat

3) JPMA News “Powder Metallurgy (Funmatsu Yakin)”

7 publications (Japanese)

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JPMA Members Regular Member: (1) PM Products Manufacturers

IWAKIDIECAST CO., LTD. OsakaYakin Kogyo CO., LTD. Kamioka Componets CO., LTD. CASTEM CO., LTD. Keiwa Seimitsu CO., LTD SUMITOMO METAL MINING CO., LTD. SUMITOMO ELECTRIC INDUSTRIES, LTD. Taisei Kogyo CO., LTD. DIAMET CORPORATION TUNGALOY CO., LTD. TEIKOKU CARBON INDUSTRY CO., LTD. TOKAI CARBON CO., LTD. TRIS Inc. NAPAC CO., LTD. Nippon Kagaku Yakin Co., Ltd. NIPPON PISTON RING CO., LTD. Hitachi Powdered Metals Co., Ltd. FINE SINTER CO., LTD. FUKUISINTER CO., LTD. FUJI-SINTERING CO., LTD. PORITE CORPORATION

(2) Metal Powder Manufacturers EPSON ATMIX CORPORATION KOBE STEEL, LTD. Sanyo Special Steel Co., Ltd. JFE STEEL CORPORATION Daido Steel Co., Ltd. TOYO ALUMINIUM K.K. DOWA ELECTRONICS MATERIALS CO., LTD. NIPPON MINING & METALS CO., LTD. Nippon Atomized Metal Powders Corporation POWDERTECH CO., LTD FUKUDA METAL FOIL & POWDER CO., LTD. Höganäs Japan K.K. MITSUI MINING & SMELTING CO., LTD. MITSUBIHI STEEL MFG. CO., LTD. MINALKO LTD.

(3) Equipment Manufacturers KOHTAKI PRECISION MACHINE CO., LTD. TAIYO WIRE CLOTH CO., LTD.

TANAKA KAME CO., LTD. Mitsubishi Materials Techno Corporation YAMAZAKI DENKI CO., LTD. YOSHIZUKA SEIKI CO., LTD.

Special Member: In-plant PM Parts Manufacturers

TOYOTA MOTOR CORPORATION

Associate Member: (1) Equipment Manufacturers

SHIMADZU MECTEM, INC. SUGAWARA SEIKI Co., Ltd.

(2) Trading Companies & Others AISIN SEIKI CO., LTD. ADTEC Engineering Co., Ltd. ITOCHU Metals Corporation Iwatani International Corporation GOSHO CO., LTD. GKN SINTER METALS (GKN Japan Limited) JFE SHOJI TRADE CORPORATION SHINSHO CORPORATION TAIYO SHOJI CO., LTD. TAIYO NIPPON SANSO CORPORATION Timcal Japan Ltd. TOYOTA CENTRAL R&D LABS., INC. *NIKKO SHOJI CO., LTD. NIPPON GRAPHITE INDUSTRIES, LTD. New Metals and Chemicals Corporation, Ltd. *Bodycote Japan K.K. Marubeni TETSUGEN CO., LTD. MAKIN METALSA JAPAN Rio Tinto Japan, Ltd. WAKOH ENTERPRISE CO., LTD.

(3) Overseas Hoeganaes Corporation KOREA POWDER METALLURGY CO., LTD. NBTM NEW MATERIALS GROUP CO., LTD. SAMHON CO., LTD.

Complimentary Member European Powder Metallurgy Association Metal Powder Industries Federation

*2009 New Member

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ANNEX: DEVELOPMENT PRIZE S. GRAND PRIX S-1 Development of high density and low loss powder magnetic core (HDMC)

for reactor in hybrid vehicles. TOYOTA MOTOR CORPORATION

DAIDO STEEL CO., LTD. TOYOTA CENTRAL R&D LABS., INC.

This product is a magnetic core of a reactor applied to the boost converter of environmental- friendly hybrid vehicles (HV). The core is made of HDMC (High Density Magnetic Composite), which is a kind of the powder magnetic core. A great cost reduction was achieved while keeping the magnetic properties equal to conventional magnetic steel.

In order to achieve both high magnetic flux density and mechanical properties of the core, high compaction density and high bending strength were coped with by developed warm compaction technique using die wall lubrication.

A great decrease of core loss was achieved by adopting the Fe-Si alloy and by developing the novel controlled atomization method which enables to make particle shape pseudo spherical.

Furthermore, the new insulating resin which has heat resistance performance of 700oC or more and the new coating technology were also developed. As the result, core loss was greatly decreased by annealing the cores at high temperature.

Compared to the conventional expensive reactor made of magnetic steel, a great material cost reduction of the core was realized due to the fabrication of net shape, the improvement of material yield, and the simplification of production processes.

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A. NEW DESIGN A-1 Development of sintered part with complicated shape for seat belt buckles

SUMITOMO ELECTRIC INDUSTRIES, LTD. This product is used for a seat belt buckle with the newly

developed safety and smaller size mechanism. Thin wall thickness “1mm”, long over all length “22mm”, and complicated shapes of end faces had to be realized. In addition, the axis function for rotating in a buckle is also needed.

MIM (Metal Injection Molding) method is generally applied for this kind of parts. However we succeeded realized the compaction with “this long length, thin wall thickness, and complicated shapes”, and stainless steel shaft press-fitting was applied for the axis function. As a result, the mass production of this sintered product was realized.

The points of this development are; 1. Uniform density for complicated shape at end faces by powder splash pocket of die. 2. Prevention of low density at neutral zone by using the moving core rod system. 3. Prevention of parts cracks by “minimizing press fitting force” and “well control of press fitting

process”. A-2 Housing with sprocket having high density and high dimensional

accuracy Hitachi Powdered Metals Co., Ltd.

This application is used in a variable valve timing system, which corresponds to silent chain system.

It is required to have good contact fatigue strength on the teeth portion and highly dimensional accuracy. Higher density is preferred to obtain good contact fatigue strength, so “rolling” on teeth portion was generally measure. But “rolling” was not useful in this case because of its specific shape teeth. Therefore, in this application, high density (7.3 g/cm3 over) on the whole of the sprocket portion was achieved by just a compacting.

There is a just small gap between inner diameter of the sprocket portion and out diameter of the housing portion in the application. Additionally, the application has 6 radiate grooves on the out diameter of the housing for the assembly process. Considering the shape, it was supposed to have some compacting issues such as follows. 1) Seizure on tooling. 2) Cracks, which is caused by tooling deflection during compaction. 3) Out of dimensional specification. These are well known to become remarkable under higher compacting pressure.

To meet these forecasted issues, using CNC-press, optimization of shoulder die shape, improvement on the assemble process and optimization of rigid balance between tooling and die-set were adopted.

Also decreasing dimensional distortion after both sintering and heat treatment was important to meet dimensional request of the application. Therefore, green density was found to have to be tightly controlled within 7.35-7.40 g/cm3. Also to prevent distortion and quenching crack after heat treatment, induction

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hardening with “Marquenching” was adopted. With these improvements, high dimensional accuracy was achieved. A-3 Development: Parts for 4WD switching actuator

PORITE CORPORATION This item is for an actuator to switch between

4-WHEEL-DRIVE and 2-WHEEL-DRIVE in recreational vehicle. This item requires high-accuracy and high-strength, therefore, forged product (Material: S45C) with cutting work was used. Especially, angle accuracy of the area between fan-shaped projections is essential. This accuracy of forged productions is ±1°, but angle dispersion is too large to satisfy item requirement. And it has cost problem due to many cutting process. In this development, producing by sintering was achieved with accuracy improvement and effective cost reduction. To satisfy angle accuracy (±0.5°) of the area between fan-shaped projections, high-accuracy was designed by preventing dimensional accuracy reduction after sintering by cracks of thin flange or density difference, by improving the tooling composition for angle accuracy and by integrating tooling of upper punch with fan-shaped projection. Also weight saving was designed by elimination of functionally unneeded part. Material is Fe-Cu-Ni-Mo-C series for securing of strength and dimensional accuracy after sintering. Moreover stabilizing positional accuracy of eccentric boss and slot with tooling by comparison with forged product with many cutting process is designed. And cheap surface treatment method is adopted for cost reduction.

As a result, this item achieved angle accuracy is ±0.14°, reduced by 25% unit weight and reduced by 50% cost. Also actuator changeover time is shortened and feeling at changeover is much smoother. This development contributes improvement of reliability and safety and downsizing of total system. B. NEW MATERIALS B-1 Low friction and low noise iron-bronze sintered bearing material which

replaces bronze bearing Hitachi Powdered Metals Co., Ltd.

A Newly developed iron-bronze sintered bearing material has low friction coefficient and low sliding noise; it is effective for down sizing and decrease noise for motors of automotive applications.

Developed material shows the lower friction coefficient as 35% in comparison with the bronze (Cu-Sn-MoS2) sintered bearing. In addition, it reduces an electric current and noise in actual power window motor.

Trends of the in-vehicle motors such as power windows, power seat are downsizing, reduction of the noise and cost reduction.

The efficiency improvement of the motor is important for the downsizing of the motor, and the bearing of a low friction coefficient is necessary. On the other hand, reduction of sliding noise of the bearing is important for reduction of the motor noise. We attended to reducing the metal contact between bearing and shaft on developing a new bearing material of the low noise in a low friction coefficient.

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The bearing material based on iron-bronze series to the less-expensive materials which considered a cost. In order to reducing metal contact between bearing and shaft, it is effective that the oil film holding

capability is improved by the refinement of the pore in sintered bearing. Conventionally, the technique of the refinement of the pore by the increase density and using of the fine powder has mainly been applied. However, there are some problems, such as lower life of the sintered bearing, because of decrease of oil content by high density. We developed the new iron-bronze sintered bearing material which has not only the fine pore, but also high oil content, using high porous iron powder. The developed materials composition is an iron - bronze bearing containing bronze of 20%. The iron system bearing is inferior in seizure resistance in comparison with the bronze-based bearing, but it use the copper powder of the big aspect ratio for raw materials, and this materials that the outer layer is copper-rich have the superior seizure resistance.

As for the development the new bearing material, performance improved than the conventional bronze-based bearing and was able to contribute to the cost merit in the user greatly. B-2 Sintered oil impregnated bearing material for fan motor having low cost and

long life PORITE CORPORATION

This material is used for sintered bearing used in fan motor of televisions, computers, game consoles, etc. Conventionally ball bearings are used for this range of applications, however, with the development of

this material, low cost and long operation life was achieved making it possible to use sintered bearings for the first time.

In this research, the amount of non-ferrous component in the materials presently used for fan motors with expected life less than 40000 hours was reduced and by using a powder with fine air pores along with low temperature sintering conditions an improvement in the sliding properties along with a reduction in the bearing attack on the shaft was achieved. Moreover, the addition of zinc further reduced the corrosion of the bearing. The life of the bearing was further increased by developing a high performance lubricant having better evaporation, better thermal stability, better low temperature property, better compatibility with resins compared to commercial lubricants. From the above results it can be concluded that a 40% reduction in raw material cost and 2.5 times increase

in the bearing life to 100000 hours was achieved.

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C. PROCESS DEVELOPMENT C-1 Development of the oil-impregnated bearing for irregular-shaped housing

DIAMET CORPORATION This process is compacting technology of the reduction of porosity

at outer surface of the oil-impregnated bearing to save oil leakage. By virtue of this, less noise and high durability are achieved by less expensive process.

When an oil-impregnated bearing is settled in an irregular-shaped housing, the bearing and the housing create a large gap between them. Because oil leakage is occurred by the gap, it causes noise and low durability resulting from metallic contact between the bearing and the shaft. In order to decrease this type of oil leakage, reduction of porosity at outer surface of the bearing is effective by machining or plating. However, the additional process decreases cost competitiveness. Although sizing with rough finished die is alternative to reduce porosity, it deteriorates roughness of the product and tooling life.

This development is compacting technology with optimized surface finished tooling to reduce porosity at outer surface of the bearing. It is confirmed that the developed bearing has smooth outer surface, and the one settled in an irregular-shaped housing satisfies low noise and high durability. As a result, the mass production of the oil-impregnated bearing is realized, and it is expected to show superiority of powder metallurgy over other methods in this type of application. C-2 Mass production of high precision clutch hub that contributes to shift change

feeling improvement FINE SINTER CO., LTD.

This process applies to manufacture of high precision sintered clutch hub for using 6th shift typed transmission for automotive.

The sintered clutch hub is a part that much influences on synchronized performance and shift feeling when shifting the transmission. Conventional process was compacting-sintering-sizing-induction heat treatment so that dimensional tolerance range of outside spline diameter (O.B.D) was 0.1mm. With demand of higher dimensional precision in order to improve shift feeling and prevent from gear removal. This time, a new process design specification that has achieved the target has been developed.

In this development, counter measures for lower strain was done with minimization of outside spline cylindricty by process analysis and with selection of material of tray and determination of sintering set procedure for sintering in order to minimize and stabilize sintering strain. Most major subject is sizing process after induction heat treatment for outside spline diameter of the hub. Consequently, a sizing correction process for outside spline diameter of it has been successful and has been established without lower strength and with prevention of crack occurrence in vicinity of the heat treated boundary area. As a result, the target that is 0.065mm as dimensional tolerance range of outside spline diameter (O.B.D.) was satisfied and mass production of high precision sintered clutch hub was realized.

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D. NEW POWDERS D-1 A new bonded mix having excellent fillability and stable apparent density,

which enables high dimensional tolerance and productivity with least loss in production. (Starmix BOOST)

Höganäs Japan K. K. Conventional bonded mixes don’t have good enough power

properties to eliminate powder and green losses particularly in case of multi level components. During setting of press and tool, during compaction campaign with repose, powder and green are lost and the operation time is lost either. In case of a product with thin section, inhomogeneous density distribution and necessity to decrease compaction speed are the problems caused by not well enough fillability.

The new bonded mix has an ideal combination of stability in apparent density and excellent fillability. Furthermore, lubricity, dusting, surface quality are significantly improved with zinc free lubricant which does not contaminate sintering furnace.

In order to realize such outstanding powder performance, a Nano technology was applied to manipulate inter-particle forces. This bonded mix is used for a multi-level synchronizing hub, improvement in both quality and productivity was proved. Powder loss at initial stage of compaction was decreased to one-tenth and the press speed was increased more two times. Dimensional tolerance of product was improved significantly. F. EFFORT PRIZE F-1 Development of a group of sintered products for manual transmission

DIAMET CORPORATION These products are 14 sintered parts, which are 8 blocks, 2 levers and 4 hubs, for a manual transmission. From the early phase of the development, application of sintered

products to the manual transmission is considered from the view points of geometry, mechanical properties, wear properties, weight and volume reduction and cost saving with the customer. As a result, the mass production of 14 sintered parts was realized successfully.

This development shows advantages of cost saving over forging, weight and volume reduction over aluminum die-casting, and wear properties over resin. From technical aspects of forming, the concavo-convex shaped block shift t/m detent part is produced by net shape forming, and the block interlock middle part is produced without machining by adopting the tapered die and optimized powder filling.

In this development, comprehensive consideration from the early stage proves functional and economical benefits of powder metallurgy to the customer, and it contributes satisfaction of the customer and expansion of PM application.

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F-2 Development: Parts for steering chilled with defective shape gear PORITE CORPORATION

This item is used for setting up the position of steering tilt feature for automobile. Up to now, not only the strength of the item, the steering position kept by the item’s friction. But now, by fitting in each other gear (between gear A and gear B) strength on retention of the steering is more secured. Moreover, gear accuracy is important in order to release the gear smoothly when adjusting the steering.

Responding to strength of the gear, the gear’s material is heat-treated carburizing (Fe-Cu-Ni-Mo-C series) and the density of gear A (7.0 g/cm3) and gear B (6.8 g/cm3). Because of this item is not perfectly a gear, by measuring the edge of gear and a part of arc in the bottom of gear is the way to measure the gear accuracy. By the way, there was a problem because the difference of the measurement result is large. So, to get the accurate gear accuracy data, we found a rule about the distance from a center of gear to an edge by feeding back the dimensional error on compressing and sintering. Moreover, there was a problem on this new steering tilt featured when releasing the gear smoothly to adjust the steering, that is because by the difference of density. In order to solve the problem, we made a tiny difference on the gear pitch and it succeed.

As a result, mass production of the steering tilt feature part achieved the requirement characteristic and measurement method of defective shape gear’s gear accuracy is established. F-3 Development of the oil pump sprocket for CVT system

DIAMET CORPORATION This product is an oil pump sprocket for CVT system with oil pump drive shaft to improve fuel

efficiency. The sprocket is required to achieve high strength, light weight, high accuracy in less expensive way. These requirements are satisfied by justification of the design geometry and heat-treatment, and the mass production of the product has been conducted successfully.

Four large asymmetric holes on the flange are designed instead of many small circle ones to achieve weight reduction. This design decreases the number of punches and reduces setup time of tooling, which results in cost reduction. Although heat deformation of thin parts created by asymmetric holes is concerned during heat treatment, optimization of heat treatment conditions is established by utilizing CAE analysis.

As a result, the mass production of high accuracy oil pump sprocket for CVT system is realized, and it shows superiority of powder metallurgy over ingot metallurgy.

JPMA Awards – Website – URL: http://www.jpma.gr.jp/en/index.html

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Secretariat: Japan Powder Metallurgy Association E-mail: apma@jpma.gr.jp

1. The 1st Board Meeting October 14, 2009 at the 1th Board Meeting in Tokyo 2. Participants Board Members President Mr. Isamu Kikuchi (JPMA, Japan)

Director Prof. Jai-Sung Lee (KPMI, Korea) Auditor Prof. Hideshi Miura (JSPM, Japan) On behalf of Prof. Mikio Takano (JSPM, Japan) Secretariat Mr. Kazunori Arai (APMA) Interpreter Mr. Toru Nakata Absence Director Mr. Chiu-Lung Chu (PMA of ROC, Taiwan) Director Mr. Deepak Varshney (PMAI, India)

Members Association JPMA (Japan) Mr. Yutaka Mizuno, President / Mr. Takashi Fukuzawa / Mr. Shinji Kiguchi

JSPM (Japan) Mr. Yoshihiro Takayama, Executive Director KPMA (Korea) No Attendance 3. Conclusion

2008-2009 Finance and 2010 Budget were approved Sites of Board Meetings in 2010 and 2011 were decided

2010: Florence, Italy 2011: Korea will be held with the 1st APMA Conference)

The establishment 0f APMA Website and Logo-Mark were decided.

April 30, 2010

Asian Powder Metallurgy Association

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PM PRODUCTION IN ASIA ○ PM Production

Source: PMAI, KPMI, PMA of ROC, JPMA (APMA members) and Powder Metallurgy Association of China General Machine Components Industry Association (CMPMA)

AREA 2007 2008 2009 09/08(%)

Japan Iron-base 115,180 108,398 72,221 66.6

Copper-base 3,440 3,264 2,419 74.1 Total 118,620 111,662 74,640 66.8

China Iron-base 91,707 86,848 90,371 104

Copper-base 5,838 5,755 5,579 96.9 Total 97,545 92,603 95,950 103.6

Korea *Iron-base 46,743 42,153 42,752 101.4

Copper-base 880 700 731 104.4 Total 47,623 42,853 43,483 101.5

Taiwan Iron-base 23,000 23,000 18,000 78.3

Copper-base 1,900 1,800 1,800 100 Total 24,900 24,800 19,800 79.8

India Iron-base 22,000 26,000 26,500 101.9

Copper-base 9,000 12,000 12,500 104.2 Total 31,000 38,000 39,000 102.6

Malaysia Iron-base 6,668 6,126 4,811 78.5

Copper-base 158 96 163 169.8 Total 6,826 6,222 4,974 79.9

Singapore Iron-base 1,037 1,214 1,067 87.9

Copper-base 658 596 495 83.1 Total 1,695 1,810 1,562 86.3

Thailand Iron-base 8,673 10,675 9,837 92.1

Copper-base 44 11 21 190.9 Total 8,717 10,685 9,858 92.3

Total Iron-base 315,008 304,414 265,559 87.2

Copper-base 21,918 24,222 23,708 97.9 Total 336,926 328,636 289,267 88

*Included “Others” ○ Application Field Ratio of PM Production (2009) (%)

AREA For

Transportation Machines

For Industrial Machines

For Electrical Machines

For Others

Japan 93 3 3 1 China 64 1 26 9 Korea 88 3 5 4 Taiwan 30 40 25 5 India 77 6 15 2 Malaysia 52 1 47 0 Singapore 33 10 56 1 Thailand 74 2 8 16