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Malleable and ductile cast irons are used extensively in automotive applications such as clutches, gears, carriers, shafts, bearings, cam, racers, hubs, etc. Recently developed P/M materials can be processed cost efficiently to replace malleable and ductile iron castings. An UTS in excess of 1240 MPa and a YS in excess of 825 MPa can be achieved with one of these new materials. These tensile properties can be coupled with elongations over 2% and impact energies over 25 Joules. This presentation will cover processing routes for these new materials and will identify parts that may benefit from this new technological advancement.

In the last several years, powder metallurgy (P/M) materials have been developed to rival the properties of cast iron and screw machined grades utilized in both automotive and non-automotive applications. These materials offer the P/M industry a momentous opportunity to dramatically increase its market by replacing some of the cast iron volume utilized today. While the inherent net shape capabilities of P/M and the potential cost savings of conversion to P/M offer customers distinct advantages, previous materials have not offered property combinations comparable to many cast iron grades. This work will explore the common grades of cast iron and propose P/M materials as possible replacements for each.

The advent of stainless steel automotive exhaust systems presents a significant opportunity for powder metallurgy (P/M) parts and the inherent economic advantages of this near net shape metalworking technology. A study was performed to determine the viability of ferritic P/M stainless steel parts for exhaust applications such as coupling flanges and hot exhaust gas oxygen sensor (HEGOS) bosses. In order to help achieve the automotive industry's stated goal of extending the functional life of exhaust components while remaining competitive, the authors developed a program to develop a database of the mechanical properties and performance characteristics of several grades of P/M stainless steel. Among the data generated and analyzed for these ferritic alloy systems are room temperature, tensile stress-strain curves, fatigue and endurance properties, hardness levels, and corrosion resistance.