Control the Distortion of the Large and Complex Shaped Parts by the Metal Injection Molding Process

Hashikawa, Ryuichi; Osada, Toshiko; Kudo, Kentaro; Tsumori, Fujio; Miura, Hideshi

doi:10.2497/jjspm.63.473

Cited by 10 publications

(6 citation statements)

References 6 publications

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“…A bimodal or trimodal powder feedstock can effectively improve the powder loading [6]. Furthermore, coarse powder contributes to the success of injection molding of relatively large parts [7]. The use of coarse powders can also enhance the debinding process.…”

mentioning

confidence: 99%

Potential of Manufacturing Low Cost MIM Stainless Steel Parts from Coarse Powders

Youhua¹,

Li²,

Jia³

et al. 2018

Int J Metall Met Phys

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Recently, metal injection molding (MIM) has emerged and rapidly developed as a powder metallurgy net-shaping process. Increasing attention has been paid to this process as a promising technology to produce small parts with complex geometric shapes [1,2]. Although MIM process is a cost-effective technology to precisely fabricate large quantities of small and intricate parts, researchers and manufacturers are highly concerned with the costly raw materials used in the process [3]. Such costly applications of MIM involve fine (< 10-20 µm) powders with spherical particle shape that are typically manufactured by gas atomization (GA) process. However, the cost of applying MIM to stainless steel (SS) powder with irregularly shaped particles using water atomization (WA) process is only one fifth of that

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mentioning

confidence: 99%

Potential of Manufacturing Low Cost MIM Stainless Steel Parts from Coarse Powders

Youhua¹,

Li²,

Jia³

et al. 2018

Int J Metall Met Phys

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show abstract

“…The significant distinction between water and gas-atomized particle manufacturing is that gas atomization makes spherical particles due to its smaller heat-carrying capacity. In contrast, water atomization, which has the largest heat-carrying capacity of any liquid, produces irregular shapes for the powder particles [50][51][52][53][54].…”

Section: Powdermentioning

confidence: 99%

Research Progress on Low-Pressure Powder Injection Molding

et al. 2022

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Powder injection molding (PIM) is a well-known technique to manufacture net-shaped, complicated, macro or micro parts employing a wide range of materials and alloys. Depending on the pressure applied to inject the feedstock, this process can be separated into low-pressure (LPIM) and high-pressure (HPIM) injection molding. Although the LPIM and HPIM processes are theoretically similar, all steps have substantial differences, particularly feedstock preparation, injection, and debinding. After decades of focusing on HPIM, low-viscosity feedstocks with improved flowability have recently been produced utilizing low-molecular-weight polymers for LPIM. It has been proven that LPIM can be used for making parts in low quantities or mass production. Compared to HPIM, which could only be used for the mass production of metallic and ceramic components, LPIM can give an outstanding opportunity to cover applications in low or large batch production rates. Due to the use of low-cost equipment, LPIM also provides several economic benefits. However, establishing an optimal binder system for all powders that should be injected at extremely low pressures (below 1 MPa) is challenging. Therefore, various defects may occur throughout the mixing, injection, debinding, and sintering stages. Since all steps in the process are interrelated, it is important to have a general picture of the whole process which needs a scientific overview. This paper reviews the potential of LPIM and the characteristics of all steps. A complete academic and research background survey on the applications, challenges, and prospects has been indicated. It can be concluded that although many challenges of LPIM have been solved, it could be a proper solution to use this process and materials in developing new applications for technologies such as additive manufacturing and processing of sensitive alloys.

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“…However, powders containing coarse irregular particles typically produced by water atomisation lead to a higher brown strength (i.e. the strength of the part after debinding), when compared with spherical powders, and allow the manufacture of larger complex shape components, while reducing the overall production cost [16,17]. Although the influence of particle size on the moldability, debindability and sinterability of MIM components has been demonstrated for spherical powders [18,19], the effect of this key parameter for irregular powders has only been addressed by a few research groups, all using high-viscosity feedstocks adapted for conventional HPIM technology.…”

Section: Introductionmentioning

confidence: 99%

Effect of powder particle shape and size distributions on the properties of low-viscosity iron-based feedstocks used in low-pressure powder injection moulding

et al. 2021

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Low-pressure powder injection moulding (LPIM) is a cost-effective manufacturing technology used to fabricate complex-shaped parts with high mechanical properties at low-or highvolume production. This research work presents an experimental approach to investigate the debound/sintered properties of iron components produced by the LPIM process using iron-based powders exhibiting different particle shapes and size distributions. Four lowviscosity feedstocks were mixed and injected into a rectangular mould cavity before being thermally wick-debound and finally sintered using identical debinding and sintering cycles. This study confirms that both irregular and spherical iron powders can be shaped via the LPIM process. The solid loadings obtained with these two powder morphologies, varying from 58 to 62 vol.-%, represent expected values. The trend in the density values obtained with irregular (∼6.6 g/cm 3 ) and spherical (∼7.5 g/cm 3 ) powders was validated by metallographic observations.

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Control the Distortion of the Large and Complex Shaped Parts by the Metal Injection Molding Process

Cited by 10 publications

References 6 publications

Potential of Manufacturing Low Cost MIM Stainless Steel Parts from Coarse Powders

Potential of Manufacturing Low Cost MIM Stainless Steel Parts from Coarse Powders

Research Progress on Low-Pressure Powder Injection Molding

Effect of powder particle shape and size distributions on the properties of low-viscosity iron-based feedstocks used in low-pressure powder injection moulding

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