The customer is part of the development process
Höganäs conducts proprietary and sector-wide research in powder metallurgy to continue developing technology and potential applications that utilise the qualities of metal powder. Höganäs also uses close collaborations with customers as a link in developing tailored products with good environmental characteristics. One example is its collaboration with Toyota, described below, where Höganäs products helped the Company take another step towards its vision of zero materials losses.

Case 1 - Höganäs helps Toyota approach its vision of zero material losses

Toyota has succeeded in cutting material losses to 0.05% when producing synchromesh clutch hubs in gearboxes using Höganäs’ powder technology.

Toyota is synonymous with the lean production concept, and constantly endeavours to make all production processes as flexible as possible so Toyota always produces exactly what is needed, when it is needed. With fast and frequent realignments, minimizing material losses is even more important.

Toyota had already made a lot of progress in reducing these losses before it started collaborating with Höganäs. Specifically, it wanted to improve the production of a synchromesh clutch hub in a gearbox. Toyota wanted the final product to have a better surface finish, to reduce post-processing as much as possible, thus cutting waste. This required components being pressed with less variation in final dimensions and with minimal weight differences  between units.

Höganäs’ response to this challenge was an innovative approach to binding agents and processing powder during pressing. The concept was based on a new mixing concept, Starmix Boost, thanks to Höganäs’ leading-edge PM resources.

The new powder mix has resulted in a new synchromesh clutch hub that is extremely stable in terms of density and weight. Waste is reduced, and the other-wise-frequent adjustment of press settings has been eliminated, saving time. Material losses have been reduced to a twentieth of traditional methods and materials. Thus a sharp reduction in post-processing operations has been achieved.

This collaboration has benefited both parties. Toyota has been able to take another  step towards its vision of zero materials losses, while Höganäs has pushed the limits of powder metallurgy further.

Case 2 - Höganäs Somaloy secures  SEM a major order from Scania

Truck maker Scania can now satisfy the EU’s new exhaust directive better than competitors thanks to SEM’s skills and Höganäs’ SMC powder.

Scania has followed its own path towards satisfying new EU and US truck emission directives. Instead of cleaning emissions on their way out from engines using various types of catalytic converter, the Company chose to build a new engine that uses fuel more efficiently, generating less emissions in the ignition process.

To succeed, a new approach and several new design features were necessary, especially in the actual fuel injection process. Scania developed a new fuel injection system in collaboration with one of the world’s leading truck engine manufacturers, Cummins of North America. Briefly, the solution injects fuel faster, more often and at higher pressure than before.

To achieve this, one precondition was to create a new type of stator, the component that opens the engine inlet valve. SEM in Sweden secured this assignment, and brought completely new qualities to a stator. The only way to attain the right magnetic characteristics was to use Höganäs’ Somaloy SMC powder.

“This is a very significant order for us,” commented Andreas Johansson, SEM’s Project Manager, “we wouldn’t have got it if we had been unable to achieve the magnetic characteristics that Höganäs Somaloy makes possible.

”SEM’s collaboration with Burgess-Norton in the US, which presses the pow-der, was an important part of its success. Burgess-Norton has long-term experience of pressing magnetic powder, and has made substantial investments in developing the skills and tools for high-performance SMC powder components.

“Thanks to our collaboration with Höganäs, and their Somaloy powder, we can now press stator components with far higher densities than previously, and with extremely consistent quality. This gives them improved magnetic characteristics, so they respond to electrical impulses faster and more strongly. The result is better valve performance,” added Ted Baker, Director of Soft Magnetics at Burgess-Norton.

Scania and Cummins also appear to be satisfied with the stator–after just a year, they doubled their order levels. The Euro 5 emissions directive comes into effect in October 2009, when Scania will be the only truck manufacturer that can offer engines that do not use exhaust cleaning systems that take up room and need maintenance. Scania’s solution also enables lower fuel consumption, which is good for the environment and total cost of ownership.