Rapid Debinding of Injection Moulded M2 High Speed Steel Using Palm Stearin/Waste Rubber Binder

2014 ◽  
Vol 879 ◽  
pp. 112-118 ◽  
Author(s):  
Noraini Abd Wahab ◽  
Mohd Afian Omar ◽  
Rosliza Sauti ◽  
Nor Amalina Nordin ◽  
Ismail Nasiruddin Ahmad
Keyword(s):  
Stearic Acid ◽  
Injection Moulding ◽  
High Speed ◽  
High Speed Steel ◽  
Palm Stearin ◽  
Complete Removal ◽  
Binder System ◽  
Waste Rubber ◽  
Vacuum Atmosphere ◽  
Debinding Process

Tendency of injection moulded parts to necessitate a long debinding time which consequently leads to an increase of defects formation has been a major obstacle for the economic process of Metal Injection Moulding (MIM). In the present study, a novel binder system based on waste rubber has been formulated in injection moulding of Molybdenum High Speed Steel (M2 HSS). The feedstock consisted of M2 HSS powder with mean diameter particle size of 16μm and binder which comprised of palm stearin, polyethylene, waste rubber and stearic acid. The moulded part was immersed into n-heptane at 60°C in order to remove the palm stearin and stearic acid, followed by sintering in a controlled vacuum atmosphere. Results showed that solvent extraction debinding technique allowed complete removal of palm stearin and stearic acid from the injection moulded part within 3 hours without swelling or distortion of the debound part. In addition, this study has demonstrated that, the novel binder system has successfully shorten the debinding time through a single stage debinding process whilst the sintered part possessed approximate density of 8.1 g/cm3 and hardness of 76.9 HRC.

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,

The Influence of Sintering Atmosphere for Metal Injection Moulding M2 High Speed Steel

2014 ◽  
Vol 879 ◽  
pp. 169-174
Author(s):  
R. Sauti ◽  
N.A. Wahab ◽  
M.A. Omar ◽  
I.N. Ahmad
Keyword(s):  
Mechanical Properties ◽  
Injection Moulding ◽  
High Speed ◽  
High Speed Steel ◽  
Steel Powder ◽  
Sintering Atmosphere ◽  
Temperature Range ◽  
Waste Rubber ◽  
Vacuum Atmosphere ◽  
M2 High Speed Steel

This paper reports on the compatibility of waste rubber as binder for M2 High Speed Steel injection moulding. The feedstock was prepared at a powder loading of 65 vol.% using 22μm M2 High Speed Steel powder and the binders consisting of 55wt.% paraffin wax, 21wt.% polyethylene, 14wt.% waste rubber and 10wt.% stearic acid. The specimens were then sintered in vacuum and 95%N2/5%H2 atmosphere. The sintering in vacuum atmosphere occurred within a temperature range from1200°C to 1260°C, whilst the 95%N2/5%H2 atmosphere was carried out within a temperature range from 1220°C to 1300°C. The effects of the sintering atmosphere and temperature on the physical properties, mechanical properties and microstructure were investigated.

Effects of Binders System on Sintered Properties of Metal Injection Molding Parts of M2 High Speed Steel

2014 ◽  
Vol 1024 ◽  
pp. 201-204 ◽  
Author(s):  
Rosliza Sauti ◽  
Nor‘aini Wahab ◽  
Mohd Afian Omar ◽  
I.N. Ahmad
Keyword(s):  
Injection Molding ◽  
High Speed ◽  
High Speed Steel ◽  
Palm Stearin ◽  
Steel Powder ◽  
Paraffin Wax ◽  
Metal Injection Molding ◽  
Waste Rubber ◽  
Vacuum Atmosphere ◽  
M2 High Speed Steel

This paper reports on the compatibility of waste rubber binder combined with conventional binder, paraffin wax and local binder, palm stearin for M2 High Speed Steel injection molding in order to obtain the better properties. The feedstock was prepared at a powder loading of 65 vol.% using 22um M2 High Speed Steel powder and the binders consisting of 55wt.% paraffin wax/palm stearin, 21wt.% polyethylene, 14wt.% waste rubber and 10wt.% stearic acid. The specimens were then sintered in vacuum atmosphere within a temperature range from 1200°C to 1260°C. The results shown even the best properties is obtain from the conventional binders, paraffin wax, thus the properties of local binders palm stearin is still comparable and good. The maximum density of paraffin wax binder was 8.095g/cm3 achieved at temperature 1250°C and palm stearin binder was 8.111g/cm3 achieved at temperature 1240°C. Therefore, in term the best strength of paraffin wax was 2351Mpa whilst palm stearin was 2210MPa, both recorded at temperature 1230°C.

Influence of Waste Rubber on the Properties and Microstructure of Injection Moulded M2 High Speed Steel

2013 ◽  
Vol 845 ◽  
pp. 939-944
Author(s):  
Noraini Abd Wahab ◽  
Mohd Afian Omar ◽  
Nor Amalina Nordin ◽  
Rosliza Sauti ◽  
M.D. Kamal Bahrin
Keyword(s):  
Stearic Acid ◽  
Injection Moulding ◽  
High Speed ◽  
Multicomponent System ◽  
High Speed Steel ◽  
Paraffin Wax ◽  
Vacuum Sintering ◽  
Waste Rubber ◽  
Homogenous Distribution ◽  
M2 High Speed Steel

New feedstock formulation for metal injection moulding (MIM) of Molybdenum High Speed Steel (M2 HSS) has been developed. The binder is a multicomponent system consisting of major binder paraffin wax (PW), stearic acid (SA) and minor binder polyethelene waste rubber (PEWR). Injection moulding was conducted successfully using a powder loading of 0.65. Scanning electron micrograph of the green injection moulded part revealed homogenous distribution of the M2 HSS particles in the wax matrix. Paraffin wax and stearic acid were driven off by immersing the injection moulded part into n-heptane for five hours. Vacuum sintering of the brown parts at a temperature range of 1240°C-1280°C resulted in high quality M2 HSS parts. The properties of the sintered part such as physical, mechanical and microstructure were studied and discussed to evaluate the influence of waste rubber in MIM of M2 HSS.

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.

Research on the Way of Obtaining the Parts of Sintered Powders by Injection Moulding

2011 ◽  
Vol 672 ◽  
pp. 237-240
Author(s):  
Liviu Brânduşan
Keyword(s):  
Stearic Acid ◽  
Injection Moulding ◽  
Complex Shape ◽  
Rheological Characteristics ◽  
Binder Removal ◽  
Injection Process ◽  
Process Deployment ◽  
Debinding Process ◽  
Small Parts

For obtaining small parts with complex shape, for which a finishing operation cannot be applied easily, injection forming can be used. For a successful applying of this procedure not only the conditions of the injection process deployment must be taken into consideration, but also the conditions of the binder removal. These conditions impose, in a big measure, the feedstock characteristics, especially the ones of the binder used. The characteristics of the binder mixed with powder influence the injection process, the debinding process and the quality of the injected and sintered parts. Regarding that the binders used are formed from many components, it is very important to know the measure that each of them determines the rheological characteristics of the mixture. In the research made, a binder was used formed from polyethylene, paraffin and stearic acid, a binder which is often used to obtain mixtures for injection. It was watched how these components influence the binder characteristics, the injection process deployment and the effect they have on the quality of the debinded parts.

Metal Injection Moulding (MIM) of M2 High Speed Steel Using a Polyethylene Based Binder

2003 ◽  
Vol 426-432 ◽  
pp. 4361-4366 ◽  
Author(s):  
Gemma Herranz ◽  
B. Levenfeld ◽  
A. Várez ◽  
José M. Torralba
Keyword(s):  
Injection Moulding ◽  
High Speed ◽  
High Speed Steel ◽  
Metal Injection Moulding ◽  
M2 High Speed Steel

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.

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