APMA Forum 2011 1

30th Oct 2011

Norhamidi Muhamad

Dept. of Mechanical Engineering, Universiti Kebangsaan Malaysia

Overview of Powder Metallurgy Activities in Malaysia

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Presentation outline

Introduction – Malaysian Powder Metallurgy and Particulate Materials Association (MPM2A)

Overview of PM Activities - Industries

Overview of PM Activities – Research Center and Universities

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Malaysian Powder Metallurgy and Particulate Materials Association (MPM2A)

Registered officially on 1 Jun 2009

1st AGM - 12th August 2009

Objective of MPM2A The general

objective: to promote research and development as well as commercialisation in the field of Powder Metallurgy and Particulate Materials in Malaysia.

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MPM2A : Activities

Powder Metallurgy and Particulate Material Symposium 1st – AMREC, SIRIM, Kulim Kedah (2007)

2nd – UITM, Shah Alam (2008)

3rd – UKM, Kuala Lumpur (2009)

4th – AMREC, SIRIM, Pulau Pinang (2010)

5th – UKM, Kuala Lumpur (14th -15 Dec 2011)

Talk to industries - cooperation with Malaysian Investment Development Authority (MIDA) Nov 2009 – Seminar and Business Matching Programme: MIM workshop

Identify as one of the target area (Pioneer status-tax incentives)

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MPM2A: Activities..

3rd Powder Metallurgy and Particulate Material Symposium: 12-13th August 2009.

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PM Activities – Industries

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PM Activities - Industries

Three major companies producing parts using PM technologies

Sumitomo Electric Sintered Components (M) Sdn. Bhd. (1989)

Porite (M) Sdn. Bhd. (1991)

Diamet Klang Malaysia Sdn. Bhd. (1992)

One company producing part using MIM

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Sumitomo Electric Sintered Components (M) Sdn. Bhd.

Product focus Car and motorcycle parts Parts for Air con and refrigerator compressor Others(Bicyle,power tools electrical parts)

Powder Usage

Manpower : 350 workers

Components for automobiles and motorcycles

Compressor parts for air-conditioners

and refrigerator

Ton

Iron Powder Reduced Atomised

350 3911

Copper 68

Graphite 35

Lubricant 31

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Sumitomo Electric Sintered Components (M) Sdn. Bhd.

Sales

Issues Manpower- difficult to get local people to join our company for the

operator level Tool Making -Still need to purchase from Japan for complex tools and

lead time to deliver the tools about I month

Sales Forecast Year 2010 2011 2012 2013 2014 RM(mil) 76 78 82 84 85 Ton 4007 4140 4584 4680 4884

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Porite (M) Sdn. Bhd.

Product focus oilless bearing and pinion gear Automotive parts Electronic/ electrical parts / Home appliance

Powder Usage

Manpower : 170 workers

Ton

Copper/bronze 104

Brass 206

Iron 85

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Porite (M) Sdn. Bhd.

Sales: 2010 -RM24 million 2011 – RM 19.2 million

Issues Domestic market sales less than 20% , export 80% and effected

by USD currency exchange. Raw material/ powder metal, import from over sea and Japan.

Supply lead time longer and cost increasing.

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Diamet Klang Malaysia Sdn. Bhd.

Product focus

Application Sales Amount Ratio

4 Wheel Vehicle 2,572 46.76%2 Wheel Vehicle 2,465 44.82%Compressor 422 7.67%Others 41 0.75%Total 5,500 100%

46.76%

44.82%

7.67%

0.75%

By Application Ratio

2 Wheel Vehicle

Compressor

Others

4 Wheel Vehicle

Unit: 1,000 Malaysian Ringgit

Sales Amount Ratio

406 7.4%2023 36.8%2143 39.0%

649 11.8%279 5.1%

5500 100.0%Total

Country

MalaysiaThailand

Others

IndonesiaVietnam

7.4%

36.8%

39.0%

11.8%

5.1%

Thailand

Malaysia

Others Indonesia

Vietnam

Unit: 1,000 Malaysian Ringgit

By Country Ratio

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Diamet Klang Malaysia Sdn. Bhd.

0

1000

2000

3000

4000

5000

6000

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

KRM/month

Year

R/A Others

Thailand Malaysia

Japan

Unit : KRM/month

Diamet Klang

Sales Trend

1stFactory Expansion

South East Asia Economic Crisis

Rocker Arm Sales Start

ISO:TS16949 Certification

ISO:TS16949 Certification

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PM Activities – Research Center and Universities

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Institutions Involve in PM Research

Research Institute: SIRIM – AMREC (PM & MIM ~1996)

Unversities: UKM - (PM and MIM (1996))

USM – (PM)

UiTM (MIM ~2000)

University Petronas (PM & MIM ~2000)

UM – (PM)

UTM

UNIMAP

UNITEN

UTHM

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EXAMPLES OF PROJECT: SIRIM - AMREC Areas Project

Friction & Hard Materials Light/Ultralight Materials Ferrous Materials Magnetic Materials

*Brake Pad for Light Rail Transit (LRT) Application *Coated High Speed Steel & Tungsten Carbide Tool Insert *Cu-C Composite Collector Shoe for LRT *Titanium/Titanium Alloy for Medical Implant *Aluminium Foam and Copper Foam for Heat Sink Application *SS316L Implant using Metal Injection Technique *Structural Steel using Warm Compaction NdFeB Bonded Magnet High Energy NdFeB Sintered Magnet

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SIRIM – AMREC (MIM)

THE DEVELOPMENT OF FRACTURE FIXATION PLATES FOR ORTHOPEDIC APPLICATIONS

Comply to International Standards:

MPIF standard 35 - Materials Standards for Metal Injection Moulded Parts

ISO 5832-1 Composition D

ISO 10993- Biological Evaluation of Medical Devices Part 5 - tests for cytotoxicity- in Vitro methods

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SIRIM – AMREC (MIM)

Up-Scaling of Prototype Titanium Alloy Implant for Dental and Craniofacial Application by Powder Injection Moulding Technique using Palm Oil Based Binder System

Development of Inconel 718 Parts using Metal Injection Molding Technique for Aerospace Industry Application

Placement Implant in Animal Model

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UKM MIM Binder Development Development of Palm Oil Binder for Metal Injection Molding

Process Application of tapioca starch as a binder system

Optimisation processes parameters Micro Metal Injection Molding Flow Analysis in Metal Injection Molding Processes – Moldflow and

in house software

PM Simulation of thermal mechanical properties of Warm Compaction

Process

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Terima Kasih