PMF Industries Inc  

2601 Reach Rd
Williamsport,  PA  17701-4181

United States
570-323-9944
http://www.flowformingplus.com
  • Booth: A5019

PMF Industries is a premier contract metals fabricator combining a large array of manufacturing processes including flowforming, deep drawing/press forming, vacuum heat treating, hot spinning, machining, electropolishing, passivating, finishing, welding, engineering services, and more, enabling us to offer unique turn-key manufacturing solutions to customer design requirements. Servicing a broad spectrum of industry from aerospace and defense to commercial food processing and filtration housings, PMF can produce your manufacture needs often as a single piece construction at less cost. PMF has expertise in fabricating hollow cylindrical and conical shapes with diameters up to 48” in various metals including stainless, high strength low alloy (HSLA), maraging, titanium, cobalt alloys such as 625 and 718, brass, copper and aluminum.  AS9100D, ISO 9100:2015 and NADCAP certified. Explore the possibilities at PMFIND.COM


 Press Releases

  • Many Benefits

    flowforming yields precision, accuracy and keeps an operation competitive. by ken healy

    With manufacturing environments on a continuously evolving trajectory, the benefit has always been greater with lean and efficient manufacturing methods that provide low cost and repeatability. Although new nonme­tallic materials have been increasingly making their way into product designs, the utilization of traditional materials continues to be a large part of commer­cial and aerospace requirements.

    Aircraft engine components are of­ten an assembly of diverse parts that are manufactured using various pro­cesses. A significant number of these parts are manufactured using sheet metal forming, and the manufactur­ing is often performed in numerous steps. Furthermore, if the assembly involves welding of different parts, distortion is likely the result. With the ever-increasing costs of raw materials, machining of symmetrical parts out of forged rings is becoming less cost ef­fective, as up to 85 percent of the ma­terial can be lost to machining chips. For these reasons, the use of near net shape manufacturing methods is ap­pealing. One of these alternative fabri­cation methods is called flowforming.

    Over the last 60 years, flowforming has been used in commercial and de­fense industries; however, the process has been looked at more favorably in recent years because of the advance­ment in flowforming technology. In­dustries, such as aerospace, favor flow-forming because it lends itself well to hollow, thin-walled symmetrical shapes with close-tolerance require­ments of the wall thickness and profile.

    Also, flowforming has the ability to form many different types of materi­als. Typical applications include mate­rials such as inconel, hastalloy, colum­bium and stainless steel (austenitic, ferretic and pH type).

    Flowformed products can be pro­duced as one-piece components that are near net shape. This is very desir­able because it reduces costs when compared to multi-piece manufac­turing methods. Flowforming also provides significant cost savings in several key areas. It significantly re­duces testing requirements due to the elimination of welds, and it yields less wasted material in the finished com­ponent. Therefore, it uses less energy for manufacturing.

    Flowforming is sometimes referred to as a controlled metal-spinning pro­cess. Similar to metal spinning, the flowforming process forms various metals against a hardened mandrel.

    The difference between flowform­ing and metal spinning is that metal spinning utilizes a relatively thinner starting material and a larger diameter starting blank. Metal spinning forms the part to the mandrel or punch and usually requires the addition of external heat to keep the material malleable. This lends itself to a lack of control which results in a wide variations in wall thickness and profiles that are nei­ther predictable nor repeatable.

    Modern flowforming, which is done in ambient temperature, ensures a repeatable forming process because it uses computer modeling and CNC equipment to control the wall thick­ness and profiles to a few thousandths of an inch.

    The optimum wall thicknesses for flowformed parts ranges from .010 to .375 inches, and can be produced for less cost than other methods. Parts with a length-to-diameter ratio of 2.5 to 1 or greater typically produce the best results.

    The design of the preform is one of the most critical starting points of a successful flowformed part. Ad­vanced computer modeling helps to ensure the success of the final compo­nent by reducing development time and wasted material.

    The process of designing an opti­mal flowformed part starts by reverse engineering the end product. Under­standing the amount of volume of ma­terial in the final part is a key to deter­mining the starting thickness of the material and developing the preform. The preform is the initial shape of the part prior to flowforming.

    Each flowformed part requires a unique preform and tooling to achieve the preform shape. The preform can be created using a number of process­es including deep drawing, machining or forging.

    The flowforming process begins by rotating the preform on a hardened mandrel and compressing it with a set of two, three or four forming wheels. While the preform is being compressed it begins to form along the contour of the mandrel. The gap between the mandrel and the form­ing wheels will determine the final thickness of the finished part. This gap can change or remain constant anywhere along the length of the part, allowing for different wall thickness­es throughout the part. Flowforming is the only metal-forming process that allows the flexibility to vary the wall thickness to produce thicker and thinner sections in any combination without material removal.

    After flowforming, other process­es can be applied to the final part such as reforming, finishing and ma­chining as needed.

    Ideal Candidates

    Because the flowforming process is conducted in an ambient environ­ment, many materials cold work as a result of the amount of strain that is introduced to the material during the process. Cold working changes the mechanical properties of the metal, usually by increasing the ultimate tensile and yield strength, but also significantly reducing the elongation.

    For example, cold working of aus­tenitic stainless steel will typical­ly double the mechanical strength. 304-grade stainless steel in the annealed condition has a tensile strength in the mid 80 ksi range with elongation of about 55 percent. After a 60 percent reduction in material thickness by the flowforming process, typical mechanical properties are 160 ksi ultimate tensile, but the elonga­tion is reduced to approximately 15 percent. However, increased strain hardening is not necessarily an asset because the original product specifi­cation may have been designed based on the attributes of the starting ma­terial. In order to return the material to the original mechanical properties of the metal, flowformed parts can be fully annealed by heat treating at a specific temperature. 

    The basic limitation of flowforming is its restriction to parts that are symmetrical around a centerline. In other words, it can only be used for parts that are conical or tubular in overall shape. Not all materials can be flowformed successfully. Certain titanium alloys or tempered aluminums, for example, are not ideal metals for flowforming. In many applications, materials of 15 percent elongation or better make ideal candidates for flowforming.

    A Viable Alternative

    If you are seeking a creative and cost-ef­fective solution to complex, hollow metal shapes, then flowforming may be a viable alternative to the tradition­al fabrication and metal forming pro­cesses. Across the spectrum of indus­tries, flowforming provides a seamless, single-piece, cyclical and contoured component that answers the need for thin wall requirements.

    Moreover, flowforming saves cost by reducing the number of components in an assembly, by reducing non-destruc­tive testing due to the elimination of welds, and by efficiently utilizing ma­terial and eliminating waste. mt

    Ken Healy is executive vice president and director of engi­neering for PMF Industries Inc. You can watch a flowforming simulation at www.pmfind.com.

    xclusive feature

    Published by Knighthouse Publishing | Tel: 312.676.1100 On behalf of PMF Industries Inc. © 2019 Knighthouse Publishing. All rights reserved.

  • AEROSPACE MANUFACTURING EDITION SEPTEMBER - 16 - 2019 MANUFACTURINGTECHNOLOGYINSIGHTS.COM Top 10 Aerospace Manufacturing Solution Providers of 2019

    Introducing Premiere Flowforming

    Be it preparing an aircraft for routine surveillance or launching missiles in times of war, precision is of paramount importance in the aerospace industry. Traditionally, the requirement for precision meant high cost with limited options for manufacturability. That praxis, however, is shifting as competition and budgets are pressing the industry for greater value. This necessity has opened the door to exploring alternative methods of manufacturing that can deliver close tolerances and reliability while maintaining weight and safety considerations.

    A process that is gaining notoriety, particularly in aerospace, is flowforming. Flowforming in combination with deep drawing and other forming operations offers a high level of design flexibility and provides one of the best and most economical methods of producing high precision,rotationally symmetrical,hollow parts. Flowforming is a cold extrusion, metal-forming process that creates seamless and contoured near-net shaped components from common forms of materials. Material is only displaced, not removed during the process. Thus, unlike the common method of manufacture utilizing forgings, only to machine away up to 85% of the material, flowforming ensures the optimal utilization of raw materials, thereby reducing wastage of expensive metals and alloys.

    The team at PMF Industries, led by John Perrotto and Ken Healy, is perfecting the combination of flowforming with deep drawing, machining and other processes, as they have pioneered the technique, and are able to manufacture design challenges not achievable by flowforming alone. First, the team at PMF receives information from the customer regarding the specified part. This is followed by PMF reverse engineering the customer’s designs to establish a “preform”. The “preform” is the starting component prior to flowforming. This “preform” can be manufactured by deep drawing, forgings or machined bar. The “preforms” used in the process are engineered for each specific design or shape and is unique to each customers specification. A series of constantly spinning wheels come in contact with the material, giving it a near net shape of the final product.

    PMF’s flowforming machines are state-of-the-art Computer Numeric Control (CNC) and can hold precise control of wall thickness and profiles of ±.005” or better with final wall thickness ranging from 0.015” to 0.625”. Materials that can be flowformed include stainless steel, high strength low alloy steels, Inconel®, Hastelloy®, brass, aluminum and many other metals. The sophistication of flowforming processes has enabled PMF to produce economical and lightweight parts, including drive shafts, pressure accumulators, hydraulic cylinders, vibration dampening mounts, and accumulator housings for aircraft landing gear among others. Besides maintaining a low ‘buy-to-fly ratio’, the flexibility of the process allows PMF to combine multiple metal-forming techniques in order to increase its versatility for aerospace applications. “Our company’s uniqueness lies in the aspiration to help the engineers at the clients’ workplace get acquainted with flowforming techniques. Engineers learn the benefits of flowforming in reducing operational costs while understanding the opportunities to make more sophisticated machine parts,” explains Perrotto, President, PMF.

    Added to that, PMF takes pride in being an AS9100 certified company that ensures high-quality result delivery. The company also boasts the National Aerospace and Defense Contractors Accreditation Program (Nadcap) certification in heat treating, welding, non-destructive examination, and non-conventional machining. PMF is highly proficient in evaluating the existing design of the machine parts used by the clients and identifying the areas to increase the tolerance levels of the materials, simultaneously attempting to form a radius, based on which the roughness of machine parts at their edges would be reduced. In an instance, PMF had assisted a client in amending a machine part that was initially developed in four different sections and then welded together. In doing so, PMF helped the client avoid high costs of manufacturing. Scripting such success stories, PMF is currently focused on starting its inhouse vacuum brazing while continuing to improve its existing flowforming procedures. “With our consistent teamwork, we aim to enhance our offerings for clients, thereby addressing their challenges for efficiently,” concludes Perrotto.

    John Perrotto

    Ken Healy

    TECHNOLOGY INSIGHTS AEROSPACE MANUFACTURING SOLUTION PROVIDERS - 2019

  • PMF Industries in growth mode, looking to hire new talent

    WILLIAMSPORT, Pa.—Many aerospace engineers have been able to solve their critical metal-forming requirements with flowforming, a cold-extrusion process known for its design flexibility and economical method of producing high-precision, rotationally symmetrical, hol­low parts. But engineers in aerospace and numerous other industries are finding that they can benefit even more by taking flowforming “to the next level,” a strategy advocated by PMF Industries. 

    PMF Industries, Inc. (https://www.pmfind.com/), a precision metal forming firm in Williamsport, Pennsylvania, serves a variety of industries, such as aerospace, military, energy, filtration, and food processing equipment. The company also serves the medical, micro-electronics, pharmaceutical, pulp and paper industries.

    Ken Healy, vice president and director of engineering for PMF Industries, said in an emailed response that PMF’s biggest strength is its unique combination of processes under one roof.  While some companies do deep drawing, and others do flowforming, Healy said PMF is able to combine these processes in house to manufacture components that no one else can.

    “Our customers come to PMF because they know that we can develop a process that will result in superior quality, while also sav­ing them money,” he said. “Many times, we are able to manufacture components from sheet or plate material that our customers, histori­cally, have had manufactured from forgings or castings. By using our flowforming process, we are able to eliminate welds in components that have varying wall thicknesses throughout the profile of the part.”

    The company’s skills and experience in flowforming metals that are difficult to form, such as Inconel 625 and T-304 stainless steel, have enabled it to manufacture components for some of the world’s leading companies in fields like aerospace, energy, and filtration. 

    “Typically, in our flowforming capabilities, we process parts with a wall thickness tolerance of ±0.005 and a diameter tolerance of ±0.010,” Healy said. “In some cases, PMF is able to hold tolerances closer than typical, depending upon material and geometry of the part.” 

    In addition to flowforming, PMF offers a multitude of what it calls “concept-to-completion” custom manufacturing processes. These processes include 6,000-watt laser cutting, deep drawing with hydrau­lic presses, hydroforming, hot- and cold-form spinning, machining, heat treating, and electrical discharge machining (EDM). But the company also provides electropolishing, passivation, welding, and non-destructive testing services, among others.

    PMF is in growth mode, Healy said, and has been continuously adding to its facility since 1965. The firm’s most recent addition was a 24,000-square-foot facility that was designed and built to accom­modate its mechanical and electro-finishing processes. PMF employs about 100 team members at it 150,000-square-foot facility, located on 10 acres.

    “We are always looking to hire new talent, as well as expanding our machining department and purchasing additional flowforming machines and hydraulic presses,” Healy said. 

    One of the firm’s aerospace customers came to PMF with a static seal that had, until then, been machined from a forging. By applying multiple processes, including flowforming, PMF was able to manufac­ture the part from sheet material, reducing the amount of material waste while maintaining superior quality, Healy said.

    “We were able to provide our customer with a completed part, including machining, for one-third of what they were paying for the raw forging,” he said.

    One of the challenges was designing a manufacturing process that was able to provide all the physical dimensional requirements of the part, while still using standard sheet material. PMF needed to prove out the modified design through a series of mechanical test­ing requirements to ensure that the flowform-processed part would achieve the same structural integrity as the forged part. 

    “Through our manufacturing capabilities, engineering experi­ence, and dedicated team, we were able to work with the customer to meet all the requirements, save cost, and meet the customer’s production schedule,” Healy said.

    Processes used by PMF to manufacture the part included laser cutting, flowforming, press forming, heat treating and brazing, ma­chining, and electrical discharge machining (EDM).

    PMF is AS9100 Rev D, ISO 9001:2015 certified. The company also has Nadcap certifications in heat treating, welding, non-destructive testing (FPI) and non-conventional machining (EDM).

    This is a reprint from the October issue of Design-2-Part magazine

  • Goal is to overcome stigma and attract skilled workers

    Williamsport, Pa – October 25, 2019 – There’s a crisis facing the manufacturing industry: the lack of skilled workers. To help combat this challenge locally, PMF Industries, a leading metal’s fabricator specializing in flowforming , combined with other manufacturing processes, based in Williamsport, has established a groundbreaking apprenticeship program.

    Working closely with the Pennsylvania Department of Labor, Keystone Development Partnership, and Central PA Workforce Development Council, PMF developed a strong, innovative, state-approved Computer Numerical Control (CNC) program that is discovering—and then delivering—exactly what skilled workers are looking for in today’s career opportunities.

    “With an aging workforce, we knew if we didn’t think outside the box and use innovative ideas to attract new skilled workers, we’d be in serious trouble,” said PMF President & General Manager John Perrotto. “We were firm on the idea of establishing an apprenticeship program. But the bigger question was, how would it work? Then we had a breakthrough.”

    PMF realized the key was to truly understand the interests and behaviors of their target audience—younger workers. Focused on this, they started to formulate a strategy around the things they knew would resonate with younger workers who might have a stigma against a career in manufacturing: technology, growth opportunity, no student loan debt, and more.

    Armed with this insight, PMF developed an apprenticeship consortium with five local high schools that offer Career & Technology Center (CTC) Programs: Williamsport High School, Jersey Shore High School, Keystone Central, Sun Area Tech in New Berlin, and CPI in Bellefonte. Other Williamsport area manufacturers have since joined the effort.

    The Program

    Currently, eight apprentices are actively participating in the CNC apprenticeship program. These young people are earning while learning, and the educational aspect doesn’t cost them a dime.

    Here’s the breakdown of the 3-year program for the participants:

    • 2000 hours of paid, on-the-job training per year
    • 144 hours (1 evening per week) of classroom instruction per year
    • No educational costs for the student

    Upon completion of the state-certified program, the apprentices earn the following:

    • Three years of bonified work experience
    • Earning a good wage with great benefits
    • No student debt
    • A state-certified Journeyman designation

    “This program offers quite a positive leap into adulthood,” said PMF Executive Vice President & Director of Engineering Ken Healy. “We are creating viable career opportunities for young workers who have determined college is not in their plans, and we’re attracting the new workers we wanted. It’s a real win-win.”

    ###

    About PMF Industries, Inc.

    As the world’s premier flowforming manufacturer, PMF can produce component shapes beyond the means of conventional metal forming at a more economical price. Better yet, with our extensive range of processes we can make more than just traditional cones and cylinders; we form one-piece component shapes which nobody else can. And with all those processes under one roof, we can take our customers from design through to the finished product. One set of hands - One-piece construction - Endless possibilities.

For Technical Support with this webpage, please contact support.