Designs and Evaluations of a Gas Atomizer to Fabricate Stainless Steel Metal Powder to Be Applied at a Metal Injection Molding

2020 ◽  
Vol 833 ◽  
pp. 40-47 ◽  
Author(s):  
Sugeng Supriadi ◽  
Tsaome Indah Susimah ◽  
Muhammad Haekal Sena Akbar ◽  
Bambang Suharno ◽  
Ario Sunar Baskoro ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Metal Powder ◽  
Spherical Shape ◽  
Steel Powder ◽  
Gas Pressure ◽  
Metal Injection Molding ◽  
Powder Morphology ◽  
Melt Flow Rate ◽  
Significant Difference

Metal Injection Molding (MIM) is an application of Powder Metallurgy (PM) and Plastic Injection Molding currently being developed to produce precisely-small components. Most of the metal applications using PM are stainless steel fabricated by a gas atomizer. In this study, an atomizer is designed and fabricated to produce stainless steel powder by using a free fall gas atomization method. The stainless steel used in this study is AISI 304 atomized with the diameter sizes varying from about 3 mm, 5 mm, and 7 mm. The variables of diameter size results are the lowest melt flow rate produces the smallest mean diameter, but no significant difference on the sphericity of powder morphology. While the gas pressure variation results shows that metal powder with smaller size will be produced more using the high gas pressure. The gas atomizer have successfully produced metal powder with the size <40 μm and have a spherical shape. The well rounded sphericity for melt flowrate 0.41x10-3 m3/min, 1.14 x10-3 m3/min, and 2.24x10-3 m3/min are 60.0%, 36.0%, and 55.2% respectively.

Effect of Pressure on the Gas Atomizer to Fabricate Stainless Steel Metal Powder

2020 ◽  
Vol 833 ◽  
pp. 54-58 ◽  
Author(s):  
Sugeng Supriadi ◽  
Tsaome Indah Susimah ◽  
Muhammad Haekal Sena Akbar ◽  
Bambang Suharno ◽  
Ario Sunar Baskoro ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Metal Powder ◽  
Large Scale ◽  
Spherical Shape ◽  
Free Fall ◽  
Gas Pressure ◽  
Raw Material ◽  
Application Process ◽  
Electric Induction ◽  
Stainless Steel 304

Metal powder is used in the Powder Metallurgy (PM) application process. Most of the metals used in the PM are stainless steel made by the gas atomization process. This study uses the free fall gas atomizer. The material was used to produce the metal powder from various forms of stainless steel 304 raw material, which is melted in an electric induction furnace. This method is very practical to be applied in the large-scale metal processing industries. While the gas pressure variation results show that metal powder with a smaller size will be produced more using high gas pressure. The free fall gas atomizer has successfully produced stainless steel 304 metal powder with the size <40 μm and have a spherical shape. The well-rounded sphericity for 8 bar pressure, 10 bar pressure, and 12 bar pressure are 61.1%, 41.7%, and 37.5% respectively. It can be concluded that 12 bar pressure produces the smallest size range of powder about <40 µm with the most quantity about 1.11%wt, followed by 10 bar pressure about 0.41%wt and 8 bar pressure about 0.07%wt.

Characterization of Micro Metal Injection Molding by Using PMMA & PEG

2013 ◽  
Vol 315 ◽  
pp. 992-996
Author(s):  
Mohd Halim Irwan Ibrahim ◽  
Norhamidi Muhamad ◽  
A.B. Sulong
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Injection Pressure ◽  
Steel Powder ◽  
Mold Temperature ◽  
Point Of View ◽  
Metal Injection Molding ◽  
Volume Percentage ◽  
Shape Retention ◽  
Injection Temperature

Due to its versatility, micro metal injection molding has become an alternative method in powder metallurgy where it can produce small part with a minimal number of waste. The success of micro MIM is greatly influenced by feedstock characteristics. This paper investigated the characterization and optimization which both of them plays an important characteristic in determining the successful of micro MIM. In this paper, stainless steel SS 316L was used with composite binder, which consists of PEG (Polyethelena Glycol), PMMA (Polymethyl Methacrilate) and SA (Stearic Acid). The rheology properties are investigated using Shimadzu Flowtester CFT-500D capillary rheometer. The geometry of water atomised stainless steel powder are irregular shape, therefore it is expected significant changes in the rheological results that can influence the microcomponent, surface quality, shape retention and resolution capabilities. From rheological characteristics, feedstock with 61.5% shows a significant value with several injection parameters were optimized through screening experiment such as injection pressure (A), injection temperature (B), mold temperature (C), injection time (D) and holding time (E). Besides that, interaction effects between injection pressure, injection temperature and mold temperature were also considered to optimize in the Taguchis orthogonal array. Result shows that 61.5%vol contributes a significant stability over a range of temperature and the best powder loading from a critical powder volume percentage (CPVP) and rheological point of view. Furthermore interaction between injection temperature and mold temperature (BxC) give highest significant factor followed by interaction between injection pressure and mold temperature (AxC).

Mixing and Characterisation of Stainless Steel 316L Feedstock for Waste Polystyrene Binder System in Metal Injection Molding (MIM)

2014 ◽  
Vol 607 ◽  
pp. 83-86 ◽  
Author(s):  
Rosli Asmawi ◽  
Mohd Halim Irwan Ibrahim ◽  
Azriszul Mohd Amin
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Palm Kernel ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Binder System ◽  
Stainless Steel 316L ◽  
Palm Kernel Oil ◽  
Kernel Oil ◽  
Waste Polystyrene

This paper describes the mixing process and homogeneity analysis of a newly developed binder system based on waste polystyrene (PS) and palm kernel oil (PKO) to produce feedstock for metal injection molding (MIM). Since mixing is a critical step in MIM process, hence the mixture of powder and binder should be homogeneous and injectable. In this study, water atomised Stainless Steel powder was mixed with a new binder system consisting of waste polystyrene and palm kernel oil in a Brabender Plastograph EC rotary mixer. Several tests were performed to assess the homogeneity of the feedstock that was produced at 60 vol.% powder loadings. The 60 vol.% was chosen because the Critical Powder Volume Concentration (CPVC) of the SS316L powder was found to be 64.8 vol.%. The tests conducted were density, binder burn-out and SEM morphology observation. It was found that the feedstock shows good homogeneity and suitable for further processing in MIM.

Optimization of Injection Parameters Using 16µm Stainless Steel Powder (SS316L) at 63 Vol. %, 63.5 Vol. % and 64 Vol. % Powder Loading by Taguchi Method for Metal Injection Molding

2011 ◽  
Vol 471-472 ◽  
pp. 558-562 ◽  
Author(s):  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Norhamidi Muhamad ◽  
Mohd Fazuri Abdullah ◽  
Che Hassan Che Haron
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Surface Quality ◽  
Injection Pressure ◽  
Steel Powder ◽  
Mold Temperature ◽  
Stainless Steel Powder ◽  
Holding Time ◽  
Metal Injection Molding ◽  
Injection Temperature

In this paper, injection molding parameters are optimized using the L18 Taguchi orthogonal array for mechanical strength and surface quality of the green part. The feedstock used consists of stainless steel powder (SS316L) with the powder loading of 63 vol. %, 63.5 vol. % & 64 vol. %. The binder compositions used are polyethelene glycol (PEG-73 wt.%), polymethyl methacrilate (PMMA-25 wt.%) and stearic acid (4 wt.%). Mould temperature, injection temperature, injection pressure, injection time, holding time and powder loading ware selected as signal factors using Taghuci’s method based on literature, where these parameters were significant in MIM. Results showed that the optimum parameters are: mold temperature at 650C, injection temperature at1450C, injection pressure at 650 bar, injection flow rate at 20 m3/s, holding time at 5 s and powder loading of 64 vol.%. Analysis of Variance (ANOVA) result shown that mold temperature is the most influence in order to produce good green part’s surface quality while powder loading give the best result for green part’s strength.

scholarly journals Green density optimization of stainless steel powder via metal injection molding by Taguchi method

2017 ◽  
Vol 135 ◽  
pp. 00038 ◽  
Author(s):  
AM Amin ◽  
MHI Ibrahim ◽  
MY Hashim ◽  
OMF Marwah ◽  
MH Othman ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
Taguchi Method ◽  
Steel Powder ◽  
Stainless Steel Powder ◽  
Metal Injection Molding ◽  
Green Density

Application of Taguchi Method for Parameters Optimization in Micro Metal Injection Molding

2011 ◽  
Vol 52-54 ◽  
pp. 244-248
Author(s):  
Haw Pei Li ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong ◽  
Heng Shye Yunn ◽  
Hooman Abolhasani
Keyword(s):  
Injection Molding ◽  
Signal To Noise Ratio ◽  
Steel Powder ◽  
Mold Temperature ◽  
Parameters Optimization ◽  
Simultaneous Optimization ◽  
Metal Injection Molding ◽  
Surface Appearance ◽  
Optimal Injection ◽  
Acetate Butyrate

Optimization of injection parameters in Micro Metal Injection Molding (μMIM) was described in this study. Stainless steel powder was mixed with Polyethelena Glycol (PEG), Polymethyl Methacrilate (PMMA) and Cellulose Acetate Butyrate (CAB) to produce feedstock. Design of Experiments (DOE) of Taguchi L-27 (313) orthogonal array technique has been used to investigate the significance and optimal injection molding parameters. The signal-to-noise ratio and analysis of variance (ANOVA) are applied to study the optimum levels and effects of process parameters. Simultaneous optimization to obtain the highest green density and excellent surface appearance was discussed. The result concluded that the mold temperature (D) is the most statistically significant process parameter and its contribution to the best appearance and density is the highest.

Effects of Sintering Variables on the Physical and Mechanical Properties of Metal Injection Molding Molded 17-4 PH Stainless Steel

2021 ◽  
Vol 1028 ◽  
pp. 403-408
Author(s):  
Apang Djafar Shieddieque ◽  
Shinta Virdhian ◽  
Moch Iqbal Zaelana Muttahar ◽  
Muhammad Rafi Muttaqin
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Injection Molding ◽  
Relative Density ◽  
Physical And Mechanical Properties ◽  
High Hardness ◽  
Argon Atmosphere ◽  
Metal Injection Molding ◽  
Manufacturing Method ◽  
Small Complex

Metal injection molding (MIM) is a near net shape manufacturing technique for producing small, complex, precision parts in mass production. MIM process is manufacturing method that combines traditional shape-making capability of plastic injection molding and the materials flexibility of powder metallurgy. The process consists of the following four steps: mixing of metal powder and binder, injection molding to shape the component, debinding to remove the binder in the component, sintering to consolidate the debound parts. In this research, the physical and mechanical properties of metal injection molded 17-4 PH stainless steel were investigated with the variation of sintering temperatures (1300 °C - 1360 °C) and atmosphere conditions (argon and vacuum conditions). The relative density, microstructure, distortion, and hardness are measured and analyzed in this study. The results show that highest relative density of 87%, relative homogeneous shrinkage and high hardness are achieved by sintering at 1360 °C for 1.5 hours and argon atmosphere. At the same sintering temperature and time, sintering in vacuum shows lower relative density (81%) than that in argon condition due to pores growth. The pore growths were not observed in the argon atmosphere. It can be concluded that sintering stages more rapidly under vacuum condition. The hardness measurements result also showed that high hardness is obtained by high density parts. The optimum average hardness obtained in this study is 239 HV. However, the hardness properties results are still lower than 280 HV according to MPIF Standard 35 for MIM parts.

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