Why are we interested?

• 15 million U.S. made autos/years
• 3 lbs. of new P/M stainless potential per automobile
• 45,000,000 lbs of new P/M stainless powder parts applications

 U.S. Stainless Powder Shipments

• 5,000 tons in 2000
• 4,354 tons in 1997
• 3,484 tons in 1996

Automotive Usage of All Stainless Steel Products

• 2000 49.1 lbs/vehicle
• 1997 47.4 lbs/vehicle
• 1996 46.5 lbs/vehicle
• 1978 26.0 lbs/vehicle
• Total P/M parts to 30.8 lbs in 1997 from 15.4 lbs/vehicle in 1978

Stainless P/M Applications

• Senior rings - mirror mounts
• Exhaust flanges - door bushing
• Oxygen gas sensors - cruise CTL
• Support bracket - fuel injector seals

P/M Sensor Rings

• Over 10 years of success in Antilock Brake Systems (ABS)
• Both 410L and 434L sensor rings have performed satisfactorily over long periods of time in corrosive environments
       -- SAE PAPER 970423 2/24/97 S. SHAH

What is happening regarding exhaust systems?

• Hotter exhaust from today's lean-burn engines
• Consumers demand longer lasting components (100,000 Miles)
• Federal government mandates and 7 year warranty requirements
       -- WARDS AUTO WORLD

Stamping Stainless Steel for Flanges is a Problem

According to Joseph A. Douthett of Armco R&D Center......

• Must hold thickness to 9.5mm
• Cost and coefficient of expansion concerns
• Cracking can occur if too thick
       -- Automotive Engineering

Stainless Flanges are Not Just for Luxury Cars

• Ford Contour
• Mercury Mystique
• Corvette
• Taurus
• GM Pick Up Truck
• Ford Explorer

Ford Exhaust Flange is 1997 P/M Part of the Year

• Manifold flange connects the manifold to the exhaust pipe leading to the catalytic converter
• Three level "TULIP" shape P/M part
• Replaced 2 piece stamped and welded assembly
• Dramatic exhaust leakage reduction

Density Requirements for Exhaust Flanges

• Must achieve 7.2 To 7.3 G/CC
• Strength
• Ductility
• Weldability
• Oxidation resistance
• Corrosion resistance

P/M Flange Property Requirements

• Hot bending yield strength
• Gas sealing suality
• Hot oxidation resistance
• Saline corrosion resistance
• Good weldability

Stainless P/M Benefits for Flange Performance

Stainless P/M materials have comparable performance to wrought in the temperature regime of the exhaust system to the rear of the catalyst. Cost benefits offered by the P/M flanges over fine blanking are as much as 50%
     -- Per Pam Lee, Ford Motor Company

Conclusion
As more property data on stainless P/M and becomes available, already confident auto engineers will increase stainless P/M and design activity resulting in dramatic increase in auto and non-auto related part business for stainless oriented P/M and parts producers.