Characterization of feedstocks for powder injection molding of SiCp-reinforced aluminium composite, as potential use for automotive and light-weight applications, has been studied in this research. Al-4.5 wt.% Cu powder, SiCp and polymeric binder were pre-mixed and compounded using a twin screw extruder at 170oC prior to powder injection molding at 170 oC. Effects of varied solid loadings at 52, 55 and 58% on green properties of the feedstocks have been investigated. Experimental results showed that compounding followed by powder injection molding allowed uniform distribution of SiCp surrounding the aluminium powder. It was found that higher solid loading improved bulk density while hardness values were observed to be similar. Molded specimens of 55% solid loading provided the optimum bend strength and strain at failure. Moreover, it was observed that the opposing abrasive property with angular shape of SiCp resulted in SiCp scratching effect, leading to irregular surface of aluminium powder after injection molding. This consequence and molding porosity were expected to be responsible for relatively low density of the molded specimens, giving the difficulty in molding at higher solid loading.
