scholarly journals Experimental Investigation of Comparative Process Capabilities of Metal and Ceramic Injection Molding for Precision Applications

2016 ◽  
Vol 4 (3) ◽  
Author(s):  
Aminul Islam ◽  
Nikolaos Giannekas ◽  
David Marhöfer ◽  
Guido Tosello ◽  
Hans Hansen
Keyword(s):  
Experimental Investigation ◽  
Injection Molding ◽  
Comparative Study ◽  
State Of The Art ◽  
Ceramic Materials ◽  
Metal Injection Molding ◽  
Powder Injection ◽  
Ceramic Injection Molding ◽  
Metal Ceramic ◽  
The Right

The purpose of this paper is to make a comparative study on the process capabilities of the two branches of the powder injection molding (PIM) process—metal injection molding (MIM) and ceramic injection molding (CIM), for high-end precision applications. The state-of-the-art literature does not make a clear comparative picture of the process capabilities of MIM and CIM. The current paper systematically characterizes the MIM and CIM processes and presents the process capabilities in terms of part shrinkage, surface replication, tolerance capability, and morphological fidelity. The results and discussion presented in the paper will be useful for thorough understanding of the MIM and CIM processes and to select the right material and process for the right application or even to combine metal and ceramic materials by molding to produce metal–ceramic hybrid components.

The Study and Application of Metal Injection Molding of Fe-Ni-Co Alloy

2011 ◽  
Vol 291-294 ◽  
pp. 590-594
Author(s):  
Chi Zhang ◽  
Rong Xiang ◽  
Jing Luo
Keyword(s):  
Injection Molding ◽  
Expansion Coefficient ◽  
Electronic Packaging ◽  
Production Efficiency ◽  
Semiconductor Industry ◽  
Ceramic Powder ◽  
Production Costs ◽  
Metal Injection Molding ◽  
Powder Injection ◽  
Structure Stability

Packaging material of electronic goods requires higher strength, higher reliability, and lower expansion coefficient .What’s more, forming process is important. The Fe-Ni-Co alloy has a low expansion coefficient and good structure stability, so it is often used for packaging materials for the semiconductor industry. The shape of electronic packaging parts is so complex that the traditional manufacturing processes are difficult to form and it costs more, which greatly limits the application of Fe-Ni-Co alloy in complex electronic packaging parts. Metal (ceramic) powder injection molding (MIM / CIM) is a new near net shape technology. In this paper, we analyze the structures and characteristics of Gehause which is an electronic packaging box that has been successfully used in the MIM process to produce it. In this process, we adopted a new material of Fe-Ni-Co alloy, a specia binder and SPC (Statistical Process Control) technology which control parameters of injection molding and weight of parts. After sintering, the mechanical properties and precision of finished products meet all demands. Therefore, MIM technology can greatly improve the production efficiency, save materials and reduce production costs in producing Gehause.

scholarly journals New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4461 ◽  
Author(s):  
Dorit Nötzel ◽  
Thomas Hanemann
Keyword(s):  
Injection Molding ◽  
Material Selection ◽  
Flow Behavior ◽  
Ceramic Materials ◽  
Maximum Temperature ◽  
Powder Injection ◽  
Fused Filament Fabrication ◽  
Sintered Ceramic ◽  
Whole Process ◽  
Dependent Flow

Only a few 3D-printing techniques are able to process ceramic materials and exploit successfully the capabilities of additive manufacturing of sintered ceramic parts. In this work, a new two component binder system, consisting of polyethyleneglycol and polyvinylbutyral, as well stearic acid as surfactant, was filled with submicron sized alumina up to 55 vol.% and used in fused filament fabrication (FFF) for the first time. The whole process chain, as established in powder injection molding of ceramic parts, starting with material selection, compounding, measurement of shear rate and temperature dependent flow behavior, filament fabrication, as well as FFF printing. A combination of solvent pre-debinding with thermal debinding and sintering at a reduced maximum temperature due to the submicron sized alumina and the related enhanced sinter activity, enabled the realization of alumina parts with complex shape and sinter densities around 98 % Th. Finally the overall shrinkage of the printed parts were compared with similar ones obtained by micro ceramic injection molding.

Innovative Metal Injection Molding (MIM) Method for Producing CoCrMo Alloy Metallic Prosthesis for Orthopedic Applications

2014 ◽  
Vol 879 ◽  
pp. 102-106
Author(s):  
Noorsyakirah Abdullah ◽  
Mohd Afian Omar ◽  
Shamsul Baharin Jamaludin ◽  
Nurazilah Mohd Zainon ◽  
Norazlan Roslani ◽  
...  
Keyword(s):  
Powder Metallurgy ◽  
Injection Molding ◽  
High Performance ◽  
Slip Casting ◽  
Plastic Injection Molding ◽  
Metal Injection Molding ◽  
Powder Injection ◽  
Powder Metallurgy Process ◽  
The Cost ◽  
Plastic Injection

Powder injection molding (PIM) is a powder metallurgy process currently used for the production of complicated and near net shape parts of high performance materials [. This technique basically combines the advantages of plastic injection molding and the versatility of the conventional powder metallurgy technique. The process overcomes the shape limitation of powder compaction, the cost of machining, the productivity limits of isostatic pressing and slip casting, and the defect and tolerance limitations of conventional casting [1, 2, . According to German and Bose [, the technology of metal injection molding (MIM) is more complicated than that of the plastic injection molding, which arises from the need to remove the binder and to densify and strengthen the part. The process composed of four sequential steps: mixing of the powder and organic binder, injection molding, debinding where all binders are removed and sintering [1, 2, 3, 4]. If it necessary, secondary operations such as heat treatments after sintering can be performed [1, 2, 3, 4, .

Binder Design for Fabricating Internal Crack-Free Injection-Molded Si3N4-Based Ceramics

1991 ◽  
Vol 249 ◽  
Author(s):  
Sophia R. Su
Keyword(s):  
Mass Transfer ◽  
Injection Molding ◽  
Cross Section ◽  
Decomposition Temperature ◽  
Internal Crack ◽  
Large Cross Section ◽  
Binder Removal ◽  
Ceramic Injection Molding ◽  
Injection Molded ◽  
The Right

ABSTRACTBinder design is an important issue in ceramic injection molding technology. The binder decomposition mechanism, which involves thermodynamics, kinetics, as well as heat and mass transfer, controls the binder removal process. This process, in turn, is governed by the thermal and physical characteristics of the organic waxes used, and is the most critical step in injection molding ceramics. In this paper, we present the binder design philosophy and the method of binder selection. A systematic binder removal study focusing on heating rate, setter powder, and sublimable materials was carried out with the selected compositions. As a result of this study, we concluded that the fluid wicking controls the binder removal at the molten temperature of the binder, and the diffusion and permeation-controlled mechanism dominate at the decomposition temperature range of the binder. With the right binder selection, it is feasible to produce internal and external crack-free large cross-section injection-molded ceramic parts.

Gas Nitriding Mechanism in Titanium Powder Injection Molded Products

2007 ◽  
Vol 534-536 ◽  
pp. 361-364
Author(s):  
Toshiko Osada ◽  
Hideshi Miura ◽  
Takanobu Yamagami ◽  
Kazuaki Nishiyabu ◽  
Shigeo Tanaka
Keyword(s):  
Injection Molding ◽  
Nitrided Layer ◽  
High Reactivity ◽  
Metal Injection Molding ◽  
Powder Injection ◽  
Gas Nitriding ◽  
Process Gas ◽  
Metal Powder Injection Molding ◽  
Injection Molded ◽  
Nitriding Mechanism

Gas surface treatment is considered to be especially effective for Titanium because of its high reactivity. In this study, we investigated the gas nitriding mechanism in titanium sintered parts produced by metal powder injection molding (MIM) process. In MIM process, gas nitriding can be surface-treated subsequently after debinding and sintering process. Then, the microstructure and nitrogen content of sintered MIM parts are considered to be greatly influenced by not only nitriding conditions but also sintered conditions. In this study, the effects of sintering time on microstructure such as nitrided layer thickness and hardness was investigated. Focus was given to the effects of specimen size on nitriding process, because the size of micro metal injection molding (μ-MIM) product is so small and the specific surface of that product is so large that the mechanical and functional properties can be subject to change by nitriding.

Metal and Ceramic Micro Components Made by Powder Injection Molding

2007 ◽  
Vol 534-536 ◽  
pp. 373-376 ◽  
Author(s):  
Volker Piotter ◽  
G. Finnah ◽  
B. Zeep ◽  
Robert Ruprecht ◽  
Jürgen Haußelt
Keyword(s):  
Injection Molding ◽  
Large Scale ◽  
Ceramic Materials ◽  
Powder Injection Molding ◽  
Tungsten Alloy ◽  
Powder Injection ◽  
Scale Production ◽  
Large Scale Production ◽  
Scope Of Application ◽  
Tungsten Powders

To overcome the lack of micro manufacturing processes suitable for medium and large scale production as well as to process high resistive materials a special variant of micro injection molding is currently under development: micro powder injection molding (MicroPIM), which already enables the manufacturing of finest detailed components with structure sizes down to a few ten micrometer. In order to expand the scope of application of MicroPIM, tests are being conducted with pure tungsten powders or tungsten alloy powders. As further improvement, micro twocomponent injection molding allows, for example, the fabrication of micro components consisting of two ceramic materials with different physical properties.

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