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Improving the cooling rate of metal injection molding by implementing conformal cooling channels and a baffled hole system
Published in Artde Donald Kin-Tak Lam, Stephen D. Prior, Sheng-Joue Young, Siu-Tsen Shen, Liang-Wen Ji, System Innovation in a Post-Pandemic World, 2022
Wei-Chen Zhou, Pei-Pu Song, Jiing-Yih La, Yao-Chen Tsai, Ming-Hsuan Wang, Chia-Hsiang Hsu
Metal injection molding (MIM) is a kind of metalworking in which fine powder metal is mixed with binder material to create a feedstock that is then shaped and solidified using injection molding [1]. Unlike plastic injection molding in which the molecules of the injected part are strongly bound, powder metal and binder (such as wax) of the injected part (typically called green part) are weakly bound [2]. A process called sintering must be carried out on the green parts to evaporate wax and to bind metal particles into a coherent unit [3]. As the powder metal and binder of a green part is weakly bound during the cooling stage, the process parameters must be set appropriately; otherwise, substantial defects such as shrinkage, crack, and breaking may develop on the injected part.
Microwave Irradiation Manufacturing of Polymer Composites
Published in Sarbjeet Kaushal, Ishbir Singh, Satnam Singh, Ankit Gupta, Sustainable Advanced Manufacturing and Materials Processing, 2023
MIM is a sustainable manufacturing technique utilized for processing metals and non-metals. The evolution of processing materials is represented in Figure 2.3. MIM is the cheapest, fastest, easiest, and greenest non-conventional manufacturing technique. Products manufactured using MIM can be used in different applications like aerospace, automobile, commercial, and so on.
Influence of sintering on mechanical response of metal injection moulded parts
Published in Materials and Manufacturing Processes, 2022
Kedarnath K. Rane, Prashant P. Date, Girish N. Kotwal, Kanhu C. Nayak, T. S. Srivatsan
Metal injection molding (MIM) is a manufacturing technique that has over the years been successfully used to produce parts that offer close tolerances while concurrently being able to produce in large quantities. Metallic parts having a high degree of geometric complexity can be successfully manufactured by carefully controlling the inherent functionality of the injection molding step in MIM.[1] The manufacturing technique essentially involves the following procedure.[2] The first step involves mixing of the metal powder (solid loading) with a binder [usually an organic binder that contains paraffin wax, such as high-density polyethylene (HDPE) and stearic acid] and termed as feedstock preparation. Injection molding of the feedstock is the forming step for obtaining green parts. The binder component (i.e., paraffin wax) is usually removed during solvent debinding in n-heptane.[3,4] Thermal debinding is usually performed in vacuum for the purpose of removing HDPE by gradually heating up to 750ºC and using a slow heating rate. The thermal debinded parts (i.e., “Brown” parts) were highly porous primarily because all of the binder constituents were systematically removed during debinding. The “Brown” parts were subsequently sintered either in vacuum or in an inert gas, to obtain the final sintered component or part.[5,6]
A net-shape forming process of Ti–6Al–4V sphere joints
Published in Powder Metallurgy, 2021
Ce Zhang, Yu Pan, Jianzhuo Sun, Xin Lu, Jiazhen Zhang
MIM is a well-established, cost-effective method to fabricate near-net shape metal components, which mainly consists of four steps: mixing, injection molding, debinding and sintering. In the MIM Ti components, there have been serious challenges in recent years. The first is to find suitable binders, which tend to introduce impurities into the as-sintered Ti MIM bodies due to their depolymerisation during the debinding and sintering [10,11]. For another, currently, Ti MIM parts run up to a foot in length, but parts over 2–4 in. are rare. The limiting factors are mainly dimensional shrinkage and impurities level because dimension control of large parts becomes more difficult to make due to the loss of shape during shrinkage. Further, large overhanging areas become difficult to control dimensionally due to gravity [12,13]. Therefore, it is of great interest to investigate the fabrication of high-performance and high-precision MIM Ti hollow sphere joints.
Effect of polypropylene as the backbone of MIM feedstock on the micro-structural phase constituents, mechanical and rheological properties of 4605 low alloy steel compacts
Published in Powder Metallurgy, 2020
V. Momeni, H. Zangi, M. H. Allaei
Metal injection moulding (MIM) is a precise manufacturing process used for small-to-medium sized components. The raw material used in this process consists of metallic powder and polymeric binder system. Binders are multi-component mixtures, typically consisting of a backbone to which various additives, like dispersants, plasticisers, lubricants and surfactants are added [1]. Backbone stabilises the shape of the injected feedstock (green part) during debinding and up to the sintering phase. The performance of binders depends on the type and content of the backbone polymer, which provides the required strength to the green parts after the injection moulding phase through debinding and up to the sintering phase [2].