Metal Injection Moulding of ZK60 Magnesium Alloy Powder Using Palm Stearin Based Binder System

2012 ◽  
Vol 445 ◽  
pp. 374-379 ◽  
Author(s):  
Mohd Ruzi Harun ◽  
N. Muhamad ◽  
Abu Bakar Sulong ◽  
N.H. Mohamad Nor ◽  
K.R. Jamaludin
Keyword(s):  
Magnesium Alloy ◽  
Injection Moulding ◽  
Alloy Powder ◽  
Physical And Mechanical Properties ◽  
Palm Stearin ◽  
Binder System ◽  
Metal Injection Moulding ◽  
Moulding Machine ◽  
Temperature And Pressure ◽  
Zk60 Magnesium Alloy

This paper presents a new fabrication process for producing magnesium alloy components via metal injection moulding (MIM). Here, four kind of feedstock with 62, 64, 66 and 68% powder loading were prepared by a mixture of gas atomized ZK60 magnesium alloy powder with a resin consisting of palm stearin and low density polyethylene. The rheological investigation of the feedstock was carried out and the optimal powder loading was determined. The optimal powder loading feedstock was then injected by screw type injection moulding machine. The effects of injection moulding parameters on the physical and mechanical properties of green compacts were evaluated. The results showed that injection moulding of a feedstock containing 64% magnesium alloy was possible at high barrel temperature and pressure.

Metal Injection Moulding of ZK60 Magnesium Alloy Powder Using Palm Stearin Based Binder System

2012 ◽  
Vol 445 ◽  
pp. 374-379 ◽  
Author(s):  
Mohd Ruzi Harun ◽  
N. Muhamad ◽  
Abu Bakar Sulong ◽  
N.H. Mohamad Nor ◽  
K.R. Jamaludin
Keyword(s):  
Magnesium Alloy ◽  
Injection Moulding ◽  
Alloy Powder ◽  
Palm Stearin ◽  
Binder System ◽  
Metal Injection Moulding ◽  
Zk60 Magnesium Alloy

The Development of Metal Injection Moulding for ZK60 Magnesium Alloy Using Palm Stearin Based Binder System

2011 ◽  
Vol 230-232 ◽  
pp. 1199-1203 ◽  
Author(s):  
M.R. Harun ◽  
N. Muhamad ◽  
A.B. Sulong ◽  
N.H. Mohamad Nor ◽  
K.R. Jamaludin
Keyword(s):  
Magnesium Alloy ◽  
Injection Moulding ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Weight Percent ◽  
Binder System ◽  
Machine Model ◽  
Moulding Machine ◽  
Zk60 Magnesium Alloy ◽  
Good Workability

In this paper, the development of green compact of ZK60 magnesium alloy was studied in the context of MIM using screw type injection moulding machine model Battenfeld BA250CDC. The MIM feedstock used was 64 vol.% powder loading and the balance was palm stearin and low linear density polyethylene with the fraction of 60/40 by weight percent. The injection moulding parameters were then adjusted until the optimal condition of green part was accomplished. Results indicate that the feedstock exhibited good workability when injection moulded at the temperature of 190°C, injection pressure of 900kN, flow rate of 15,5cm3/s and with a very low ejection parameters. This technique provides an additional means to manufacture magnesium alloy components for a wide variety of applications.

Metal Injection Moulding of Hip Stem CoCrMo Alloy Powder Using Palm Stearin Binder System

2016 ◽  
Vol 1133 ◽  
pp. 334-338
Author(s):  
Mohd Afian Omar ◽  
Noorsyakirah Abdullah ◽  
Rosliza Sauti ◽  
Nurazilah Mohd Zainon ◽  
Nurhaslina Johari ◽  
...  
Keyword(s):  
Stearic Acid ◽  
Injection Moulding ◽  
Alloy Powder ◽  
Palm Stearin ◽  
Complete Removal ◽  
Paraffin Wax ◽  
Binder System ◽  
Time Duration ◽  
Cocrmo Alloy ◽  
Metal Injection Moulding

Metal Injection Moulding (MIM) has undergone development of various binder systems with the aims of shortening the overall debinding time duration. In the present work, binder system based on biopolymer has been utilised in injection moulding of hip stem CoCrMo alloy powder. The feedstock consisted of CoCrMo powder with mean diameter particle size of 16μm and binder system which comprised of major fraction of wax and minor fraction of polyethylene. The moulded part was immersed into n-heptane at 60°C in order to remove the paraffin wax and stearic acid, followed by sintering in a controlled vacuum atmosphere. Results showed that solvent extraction debinding technique allowed complete removal of paraffin wax and stearic acid from the injection moulded part within 5 hours without swelling or distortion of the debound part. Lower heating rate needed during thermal pyrolysis in order to retain the shape due to the thickness of the part.Keywords: CoCrMo, MIM, wax, debinding,

Rheological Characterizations of Copper - Palm Stearin Based Binder System for Metal Injection Moulding

2016 ◽  
Vol 867 ◽  
pp. 77-80
Author(s):  
Nor Amalina Nordin ◽  
Mohammad Dahar Kamal Bahrin ◽  
Nor‘aini Wahab ◽  
Afian Omar ◽  
Muhammad Hussain Ismail
Keyword(s):  
Electron Microscope ◽  
Injection Moulding ◽  
Palm Stearin ◽  
Mixing Process ◽  
Capillary Rheometer ◽  
Binder System ◽  
Microstructural Study ◽  
Metal Injection Moulding ◽  
Scanning Electron ◽  
Good Agreement

This research paper reports the findings of feedstock establishment works for Metal Injection Moulding (MIM) of copper parts employing palm stearin based binder system. The main objective of this study is to explore an appropriate formulation of palm stearin-polyethylene (PSPE) binder system of copper feedstock that enabling the MIM process. Two formulations; 60%wt PS and 70%wt PS with constant powder loading of 60 vol. % Cu has been prepared. The mixing process of copper powder and binders was performed at the speed of 50 rpm at 160°C. Scanning Electron Microscope (SEM) has been used for the microstructural study of starting materials and mixtures. The rheological characterizarions for both formulations that were carried out using Rosand RH2000 Capillary Rheometer exhibited the pseudo plastic flow and in good agreement with previous findings.

Effect of Solid Loading on the Physical Properties of the Sintered Inconel 718 Using Metal Injection Moulding (MIM)

2014 ◽  
Vol 879 ◽  
pp. 164-168
Author(s):  
Rosdi Ibrahim ◽  
Ahmad Nizam bin Abdullah ◽  
Muhammad Jabir bin Suleiman Ahmad ◽  
Nurhaslina binti Johari ◽  
Mazlan Mohamad ◽  
...  
Keyword(s):  
Physical Properties ◽  
Injection Moulding ◽  
Inconel 718 ◽  
Elevated Temperatures ◽  
Palm Stearin ◽  
Cost Effective ◽  
High Volume ◽  
Solid Loading ◽  
Binder System ◽  
Metal Injection Moulding

Inconel 718 has been widely used as a super alloy in aerospace application due to the high strength at elevated temperatures, satisfactory oxidation resistance and heat corrosion resistance. In this study, the Inconel 718 with different solid loading (System A - 50/50 vol.% and System B - 60/40 vol.%) has been fabricated using high technology of Metal Injection Moulding (MIM) process due to the cost effective technique for producing small, complex and precision parts in high volume compared with conventional method through machining. Through MIM, the binder system is one of the most important criteria in order to successfully fabricate the Inconel 718. Even though, the binder system is a temporary, but failure in the selection and removal of the binder system will affect on the final properties of the sintered parts. Therefore, the binder system based on palm oil derivative which is palm stearin has been formulated and developed. The rheological studies of the mixture between the powder and binders system have been determined properly in order to be successful during injection into injection moulding machine. After moulding, the binder holds the particles in place. The binder system has to be removed completely through debinding step. During debinding step, solvent debinding and thermal pyrolysis has been used to remove completely of the binder system. The debound part is then sintered to give the required physical properties.

A Study of Polyvinyl Butyryl Based Binder System in Titanium Based Metal Injection Moulding

2012 ◽  
Vol 520 ◽  
pp. 167-173 ◽  
Author(s):  
G. Thavanayagam ◽  
De Liang Zhang ◽  
K.L. Pickering ◽  
Stella Raynova
Keyword(s):  
Thermal Analysis ◽  
Injection Moulding ◽  
Twin Screw Extruder ◽  
Metal Powders ◽  
Binder System ◽  
Mixing Conditions ◽  
Screw Extruder ◽  
Metal Injection Moulding ◽  
Twin Screw ◽  
Mechanical Mixer

Metal injection moulding (MIM) is an innovative injection moulding technique widely used to produce complex shaped components from feedstock composed of metal powders and thermosetting or thermoplastic binders. In MIM, binder selection and formulation are considered as critical processes since binder characteristics dictate the success of MIM. The purpose of this study is to determine the feasibility of polyvinyl butyryl (PVB) based binder system in Ti-6Al-4V(wt.%)/binder feedstock, as well as to understand the effects of key parameters, such as powder loading and mixing conditions on the rheological properties of a feedstock. In this study, PVB, polyethylene glycol (PEG), and stearic acid (SA) were chosen to formulate a multi-component binder system to prepare Ti-6Al-4V based feedstock with the aid of three types of mixers: a compounder, a modified mechanical mixer and a twin screw extruder. Further, morphological analysis was performed using optical microscopy and scanning electron microscopy. Thermal analysis was performed using simultaneous differential thermal analysis and thermogravimetric analysis. Results showed that binder formulation was reasonably successful with the aid of both mechanical mixer and a twin screw extruder under certain mixing conditions, and the critical powder loading was 68 vol.%, resulting in an optimum powder loading of 63 vol.% .

Comparison on Rheology Properties of Polypropylene and Polyethylene as Binder System with Stainless Steel 316L for Metal Injection Moding

2011 ◽  
Vol 471-472 ◽  
pp. 409-414 ◽  
Author(s):  
Mohd Fazuri Abdullah ◽  
Abu Bakar Sulong ◽  
Norhamidi Muhamad ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Nor Hamdan Nor Yahya
Keyword(s):  
Stainless Steel ◽  
Flow Behavior ◽  
Palm Stearin ◽  
High Sensitivity ◽  
Steel Powder ◽  
Binder System ◽  
Stainless Steel 316L ◽  
Temperature And Pressure ◽  
Average Size ◽  
Scanning Electron

The comparison of binder system between PP/ palm stearin and PE/ palm stearin both mixed with palm stearin were studied based on the rheological properties to (MIM) process. The microstructure of distribution and dispersion studied using scanning electron microscope (SEM) to observe the pattern of the attached binder with stainless steel powder. The types of binder system used were palm stearin with Polypropylene (PP) and Polyethylene (PE). The powder loading for stainless steel 316L with average size of 20µm used was determined at 66 vol %. The palm stearin was the main significant factor for both viscosity and sensitivity of the feedstock behavior. Less content of palm stearin reduce the viscosity of the feedstock in the range of 100-10000 Pa.s and less influence on changing towards temperature and pressure. As the percentage of addition of palm stearin increase, the feedstock becomes less viscous with high sensitivity. PP and PE feedstock shows dilatant and pseudoplastic flow behavior respectively. PE homogenously coated each of stainless during morphology observation. Meanwhile poor distribution of PP can be observed from SEM observation at 1000x magnification.

scholarly journals Application of thermal analysis in the selection of polymer components used as a binder for metal injection moulding of Co–Cr–Mo alloy powder

2018 ◽  
Vol 134 (1) ◽  
pp. 391-399 ◽  
Author(s):  
Grzegorz Matula ◽  
Błażej Tomiczek ◽  
Mariusz Król ◽  
Aleksandra Szatkowska ◽  
Maria Eugenia Sotomayor
Keyword(s):  
Thermal Analysis ◽  
Injection Moulding ◽  
Alloy Powder ◽  
Metal Injection Moulding ◽  
Selection Of
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