GKN Sinter Metals Advanced Engine Components Worldwide. Superior Performance Reduced Costs Global Supply Local Expertise

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1 GKN Sinter Metals Advanced Engine Components Worldwide Superior Performance Reduced Costs Global Supply Local Expertise

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3 No company works more closely or more successfully with the global automotive market to provide high-performance powder metal (P/M) engine components than GKN Sinter Metals. For more information on the benefits we can bring to you, please read the pages that follow Five reasons why we should be your supplier The widest range of advanced engine products Developing new technologies, delivering new solutions Global engineering and technology support The world s most advanced P/M manufacturing For your needs, rely on the P/M industry leader More about our parent company: GKN PLC One Company, One Name, One Team.

4 Five Reasons Why GKN Sinter Metals Should Be Your Engine Component Supplier Extensive experience in powder metals development and processing throughout the world. GKN Sinter Metals is the world s largest P/M engine component manufacturer. We utilize a range of manufacturing processes and features including warm compaction, green machining, powder forging and conventional powder metal pressing. We also incorporate several post-production testing and validation services to assure product quality and optimal performance. Common standards for engineering, manufacturing, finishing and product certification around the world. Simply put, GKN Sinter Metals sets the global standard for product quality. Our products meet your manufacturing benchmarks for performance and reliability, ensuring durability and cost effectiveness. The widest range of advanced powder metal (P/M) technologies and products for enhanced performance and lower costs. At GKN Sinter Metals, we continuously develop new technologies that enable more complex shape manufacturing, increase strength and reduce machining as well as materials usage. Our global research and development centers, along with technology partnerships formed with other industry experts, enable us to consistently deliver breakthrough engine products that help you increase productivity while reducing operating costs. Global presence combined with local support. With production facilities in over 30 locations, GKN Sinter Metals offers reliable local supply, combined with global powder metal development expertise. Our engineers understand the challenges of working across time zones with speed, and appreciate your need for better performing and lighter weight components everywhere you operate. World-class innovation resulting from close technological and business partnerships with our customers and suppliers. GKN Sinter Metals expert project engineers work with you from initial design and testing through product delivery to help ensure components meet your specific application needs at the lowest possible manufacturing cost. 2

5 The Widest Range Of Advanced Engine Products The global automotive industry is more competitive and demanding than ever, and engine design, development and manufacturing are key to creating better performing cars, trucks and heavy-duty vehicles. To help you stay ahead in this challenging environment, GKN Sinter Metals offers the latest engine component technologies technologies that help you meet, and even exceed, the industry s stringent demands to improve performance and lower total vehicle manufacturing costs. Backed by decades of powder metal and engine component manufacturing expertise, GKN Sinter Metals provides the widest range of advanced engine products, including: Aluminum cam caps Bed plate inserts Connecting rods Main bearing caps Oil pump components Pulse rings Stainless flanges Timing system components No other P/M component supplier can match GKN Sinter Metals expertise and commitment to the vehicle engine market. GKN Sinter Metals has been a leading producer of precision forged connecting rods for more than 10 years. From two connecting rod R&D centers and three production facilities, we support customers throughout the world. Advanced engineering capabilities, FEA analysis, stroker fatigue testing and stateof-the-art production equipment are employed to design and manufacture connecting rods in a near-net shape to significantly reduce machining time and cost. Our patented, fracture notch process allows for precise, cost-effective fracture splitting, with no need for laser notch or broaching equipment. Bearing caps and inserts at GKN have revolutionized engine design by lowering component cost, freeing up valuable customer plant space, improving quality and reducing engine NVH. With over 8 years of production, more than 16 programs successfully launched, GKN s extensive experience in Bearing Cap design positions us as the unrivaled mass production leader, and your source for design, validation, installation and machining consultation. Our patented Integral Dowel design can also guarantee precision alignment relocation after boring. GKN has a comprehensive range of equipment to supply any size pulley or sprocket for automotive timing systems. For these tough applications, we use advanced, computercontrolled, multi-level compaction presses. And, for those parts that need intricate machining (e.g., variable timing components), we ve pioneered the use of warm compaction and green or pre-sinter machining technology. In production now for more than five years, millions of P/M aluminum cam caps from GKN Sinter Metals have been used by automakers in overhead cam engines. These parts are produced to the highest dimensional accuracy and metallurgical quality, and thermal response and machinability are matched very closely to that of aluminum die cast materials. For those applications that require relocation and alignment dowels, our patented Z-loc design provides the solution. GKN has extensive experience in consultative engineering for oil pump applications, including rotor, crescent and external gear designs. We offer computerized rotor designs, theoretical performance calculations, practical performance tests, efficiency calculations, housing design optimization, production manufacturing on the latest technology equipment and rapid prototyping for your new program capabilities. 3

6 Developing New Technologies, Delivering New Solutions GKN Sinter Metals is the world s leading supplier of P/M engine components and related technologies, and it s no secret why. Around the globe, our product development specialists stay focused on understanding and responding to your specific application needs. We work hard to deliver innovative solutions that help you increase productivity, control costs and achieve quality standards throughout the world. One reason why GKN Sinter Metals is so successful as a global supply partner to the automotive industry is our ability to link design engineers and manufacturing experts around the world. When we develop new technologies for customers in far-away regions or in other industries that might improve engine performance, we immediately share them with local customers in need of that particular technical development. That means whatever your product performance or economic objective, you can consistently and confidently rely on GKN Sinter Metals to deliver what you need when and where you need it. CASE STUDY: For example, one customer required a dual-metal pole piece for a variable-assist steering system. The component, which consisted of two concentric, annular magnets with teeth, had to be produced in high volumes, to close tolerances, and with one other special requirement: the magnets had to be insulated from each other. The GKN Sinter Metals solution called for joining the magnets with a disc of non-magnetic stainless steel. To accomplish this, we poured two powders into a compaction die and sintered the dual materials into a net-shape component with the required magnetic performance. This unique P/M solution has been used successfully by the client for many years and is now in its third iteration. 4

7 Global Engineering And Technology Support A global commitment to P/M research and technology is the cornerstone of GKN Sinter Metals product development and supply philosophy. Our engineering and technology solutions are proven using advanced product testing and validation techniques that include complete threedimensional performance and economic modeling, Finite Elemental Analysis (FEA) and Rapid Prototyping all to help validate designs, material specifications and functional testing. To assure GKN Sinter Metals engine components meet or exceed your most demanding requirements, we utilize: Advanced metallurgical testing equipment ANSYS Finite Element Analysis (FEA) DEFORM plastic FEA/metal flow analysis Machinability analysis Stroker fatigue test machines Torsional torque test rigs kn servo-hydraulic axial fatigue test machines GKN Sinter Metals global research and development centers, along with technology partnerships formed with other industry experts, enable us to consistently deliver breakthrough products that help you increase productivity while reducing operating costs. 5

8 The World s Most Advanced P/M Manufacturing With over 30 manufacturing facilities around the world, GKN Sinter Metals supplies a full range of production processes and press tonnage, using the broadest spectrum of raw materials in the industry. Our advanced manufacturing techniques, including SixSigma and lean manufacturing, result in optimal manufacturing processes and lower overall manufacturing costs. Specifically, GKN Sinter Metals engine components: Achieve high dimensional accuracy, repeatability and reliability Eliminate or minimize machining and labor-intensive operations Enable complex shape manufacturing and innovative material and/or feature combinations in a single component Increase strength and corrosion resistance Minimize energy consumption Optimize material usage Reduce component weight Many GKN Sinter Metals components are formed to net or near-net shape, and require little to no secondary operations. However, we do offer complete secondary operations for finishing components, including centerless and cylindrical OD grinding, ID bore grinding and honing, precision drilling, milling, hard and soft turning operations, induction surface and through hardening, and steam heat treatment to provide additional precision or performance properties. We also provide postproduction capabilities such as our own internationally accredited laboratories that provide quality assurance certification for all parts manufactured by the company. These unique GKN Sinter Metals capabilities save you added time and costs normally associated with sending samples to outside companies and laboratories for further production and/or quality analysis. Superior Customer Service GKN Sinter Metals also provides extensive sales support services, including logistical coordination, inventory management and P/M technology training. Best of all, GKN Sinter Metals global solutions approach means you can reduce the number of vendors you normally deal with, better manage product inventory and reduce your total operating costs. GKN Sinter Metals is the world s leading powder metal component manufacturer and the number one P/M engine component supplier. Shouldn t we be serving you? 6

9 FOR ADVANCED ENGINE COMPONENTS, RELY ON THE P/M INDUSTRY LEADER To benefit from the experience, expertise and global resources of the world s leading supplier of powder metal engine components, contact us at: GKN Sinter Metals 3300 University Drive Auburn Hills, MI USA Phone: (248) Fax: (248) Internet: Commitment backed By Performance. 7

10 GKN SINTER METALS, PART OF UK-BASED GKN PLC, IS THE WORLD S LEADING FULL-SERVICE SUPPLIER OF PRECISION POWDER METAL COMPONENTS. THE COMPANY S GLOBAL TECHNICAL, MANUFACTURING AND SALES NETWORK COMPRISES SOME 7,000 EMPLOYEES AND OVER 30 FACILITIES SPANNING FIVE CONTINENTS. GKN SINTER METALS OFFERS CUSTOMERS THE BROADEST RANGE OF POWDER METAL PRODUCTS, TECHNOLOGIES AND SERVICES, FROM CONSULTATIVE ENGINEERING AND DESIGN TO PRODUCT TESTING AND THE MOST INTRICATE SINTERED PARTS. THE COMPANY S EXTENSIVE PRODUCTION NETWORK MANUFACTURES AND SUPPLIES: SELF-LUBRICATING BEARINGS SINTERED STRUCTURAL PARTS FILTER TECHNOLOGY AND PARTS WITH FUNCTIONAL POROSITY POWDER METAL INJECTION MOLDING (MIM) SOFT MAGNETIC/COMPOSITE MATERIALS POWDER FORGED COMPONENTS HIGH PERFORMANCE PLASTICS EXTENSIVE MACHINING CAPABILITIES SINCE 1950, GKN ALSO HAS BEEN INVOLVED IN DEVELOPING AND PRODUCING SINTERED METAL FILTERS THROUGH THE USE OF POWDER METALLURGY. TODAY, GKN SINTER METALS IS A WORLD-LEADING PRODUCER OF SINTERED METAL FILTERS AND COMPONENTS, WITH PRODUCTION FACILITIES IN GERMANY, INDIA, CHINA AND THE UNITED STATES. 8

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12 Commitment Backed By Performance. WORLD HEADQUARTERS GKN Sinter Metals 3300 University Drive Auburn Hills, Michigan USA Phone: Fax: SALES & MARKETING USA/Canada/South America GKN Sinter Metals 3300 University Drive Auburn Hills, Michigan USA Phone: Fax: Italy/Switzerland GKN Sinter Metals AG Fabrikstrasse Bruneck, (BZ) Italy Phone: Fax: Germany/Benelux/Austria/Eastern Europe GKN Sinter Metals GmbH Krebsöge Radevormwald, Germany Phone: Fax: Sweden/Denmark/Norway/Finland GKN Sinter Metals AB Box 101 S Kolsva, Sweden Phone: Fax: United Kingdom GKN Sinter Metals P.O. Box 3 Trent Valley Rd., Lichfield Staffordshire WS136HF, England Phone: Fax: Japan/Asia GKN Japan Sumitomo Seimei Shin-Osaka Hagashiguchi Bldg. 8F , Higashi-Nakajima Higashi-Yodogawa-ku Osaka , Japan Phone: Fax: South Africa GKN Sinter Metals-Cape Town S.A. P.O. Box 156 Bellville, 7535, South Africa Phone: Fax: France/Spain/Portugal GKN Sinter Metals France 100 Vanderbilt Avenue Carrieres sous Poissy, France Phone: Fax: Internet: GKN Sinter Metals. All rights reserved.

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