owder

1. M etals L ight P owder High Performance Aluminium Fields of Operation Development Production Marketing PM High Performance- Aluminium (micro-crystalline and nano-crystalline) Semi’s Blanks Components

2. M etals L ight P owder High Performance Aluminium Co-operations for Development and Production Powder Light Metals co-operates with chosen partners, universities and institutes worldwide on development and production optimisation • ECKA Granules Powder feedstock • FCT Systeme GmbH, Rauenstein FAST direct compaction • Morphic Technology, Sweden Adiabatic metal forming • Technical University of Berlin Extrusion optimisation • IFAM Dresden Alloy and process development • University of Stuttgart Metal forming • University of Lueven, Belgium Alloy and process development • Aluminiumwerke Unna Extrusion • Otto Fuchs Indirect extrusion

3. M etals L ight P owder High Performance Aluminium Sales and Marketing Organisation Powder Light Metals is active worldwide in sales and marketing • Burger Consulting GmbH Germany • Stadele Consulting and Engineering Italy and Germany • Aluminium Solutions in association United Kingdom and USAwith Aluminium Special Products

4. M etals L ight P owder High Performance Aluminium Requirements for high Performance Aluminium Alloys • Highest strength in combination with good fracture toughness • High strength for medium temperatures up to 400 OC • High Specific Stiffness • Excellent wear resistance • Extremely low co-efficient of thermal expansion (CTE) • Good thermal and/or electrical conductivity • Superior corrosion resistance in different environments • Good formability using standard equipment • Good machinability • Ease of recycling

5. M etals L ight P owder High Performance Aluminium Why Powder Metallurgy/Rapid Solidification? • Development and production of new micro-crystalline or nano- crystalline high performance alloys with improved properties by: - increased alloy content - additional alloying elements - superior homogeneous microstructure - nano-crystalline or quasi-crystalline microstructure • Improved hardening mechanisms from traditional precipitation hardening to dispersion strengthening or a combination of both. • Conversion of cast alloys to wrought alloys (AlSi…) • Tailor made alloys for specific applications (design for application)

6. M etals L ight P owder High Performance Aluminium Processes for Powder / Feedstock Production liquid gas atomization melt spinning gas atomization melt extraction spray compaction centrifugal atomization 7 10 K/s direct chill casting increasing cooling rates 10 K/s

7. M etals L ight P owder High Performance Aluminium Principle “Melt Spinning”

8. M etals L ight P owder High Performance Aluminium

9. M etals L ight P owder High Performance Aluminium

10. M etals L ight P owder High Performance Aluminium Pistons for IC Engines Light-weight forged piston for petrol engines • Requirements • -High Temperature strength • Fatigue strength (high temperatures) • Thermal Shock resistance • Resistance against cavitation erosion • Wear Resistance Solution RS Al Alloys by atomization or melt spinning (e.g. AlSi20–TM, AlMg20Si10-TM Local reinforcement (e.g. friction welding) of cast pistons for DI- Diesel- Engines

11. M etals L ight P owder High Performance Aluminium Lightweight cylinder liners

12. M etals L ight P owder High Performance Aluminium Light-weight materials for valve train components

13. M etals L ight P owder High Performance Aluminium Lightweight oil pump gears

14. M etals L ight P owder High Performance Aluminium CIP HIP Rolling Plates Al- B4C- Plates (20 wt.-% B4C) Application-Neutron Absorption in Nuclear Waste Containers Manufacturing- Powder Blending

15. M etals L ight P owder High Performance Aluminium Al Ni8 Mn2 Cu …… substitution of AA2618 for highly stressed components • Higher service temperatures at the same strength level • Higher strength level at the same service temperature

16. M etals L ight P owder High Performance Aluminium High Strength Aluminium Screws • Requirements: • high strength at room temperature (750 – 800 MPa) - strength at 150°C – 200°C (min. 450 MPa and 350 MPa, respectively) - good relaxation properties - creep resistance - corrosion resistance - low friction coefficient - good coating properties Applications:- Cylinder head - Gear boxes - Satellites - Split rims - Connecting rods - Bearing caps - others

17. M etals L ight P owder High Performance Aluminium PM-SiAl40; 500x Controlled linear thermal expansion AlSi Alloys • Properties: • controlled thermal expansion: 7 – 24 ppm • low densities: 2,4 – 2,7g/cm³ • high thermal conductivity: 120 – 180 W/mK • electrical conductivity: < 10-6 ohm x cm • excellent thermal stability up to 500°C • high specific stiffness • Replacements for: • Copper Molybdenum (Cu-Mo / Mo-Cu) - Copper Tungsten (Cu-W / W-Cu) - Aluminium Silicon Carbide (Al-SiC) • - Kovar • Applications : • RF and Microwave Packages • Electro-Optical Housings • Heat Sinks and Heat Spreaders • General Electronic Packages • Waveguides and Microwave Filter Components • Carrier Plates for HF Circuits • Components for Inertial Systems

18. M etals L ight P owder High Performance Aluminium Spool Valves made from PM-AlSi17FeCuMgZr (alternative to AlMgSi0,5 with Hard-Coating) Properties:- superior wear resistance without any additional coatings - excellent machinability (short chips) - non magnetic - easy burr removing • Applications : • Control Unit for Automatic Transmission • Pressure Control Valve in Oil-Pumps • Center Screw in Variable Valve Timing System (VVT)