Effect of Powder Shape and Size on Rheological, Thermal, and Segregation Properties of Low-Pressure Powder Injection Molding Feedstocks

Trad, Mohamed Aziz Ben; Demers, Vincent; Dufresne, Louis

doi:10.1007/s11665-019-04276-9

Cited by 16 publications

(13 citation statements)

References 36 publications

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“…For stainless steel 17-4PH powders mixed with a wax-based binder, the researchers [31] reported higher viscosities for PIM feedstock with a higher particle surface area. In the study of Dimitri et al [32], the authors studied the effect of shape and size of stainless steel 17-4PH powders on rheological properties of feedstock material. Their results showed that both the size and shape of the particles affected the rheological behaviour of the feedstock.…”

Section: Introductionmentioning

confidence: 99%

Rheological Behaviour of Highly Filled Materials for Injection Moulding and Additive Manufacturing: Effect of Particle Material and Loading

et al. 2020

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Within this paper, we are dealing with a mixture of thermoplastic polymer that is filled with inorganic fillers at high concentrations up to 60 vol.%. A high number of particles in the compound can substantially change the rheological behaviour of the composite and can lead to problems during processing in the molten state. The rheological behaviour of highly filled materials is complex and influenced by many interrelated factors. In the present investigation, we considered four different spherical materials: steel, aluminium alloy, titanium alloy and glass. Particles with similar particle size distribution were mixed with a binder system at different filling grades (30–60 vol.%). We showed that the rheological behaviour of highly filled materials is significantly dependent on the chemical interactions between the filler and matrix material. Moreover, it was shown that the changes of the particle shape and size during processing lead to unexpected rheological behaviour of composite materials as it was observed in the composites filled with glass beads that broke at high contents during processing.

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Section: Introductionmentioning

confidence: 99%

Rheological Behaviour of Highly Filled Materials for Injection Moulding and Additive Manufacturing: Effect of Particle Material and Loading

et al. 2020

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“…In another study, the influence of particle size and particle shape on rheological, thermal, and segregation properties were investigated for typical 17-4 PH feedstocks used in the LPIM process by Trad et al [36]. Four different powder lots were used in this study with the d 90 of 5.4, 20.3, 31.3, and 27.5 µm, respectively.…”

Section: Powdermentioning

confidence: 99%

“…In the research work from Trad et al [36], the solid loading was set at 60 vol.% powder to make four different feedstocks with the same low melting point binder system of 30 vol.% PW, 7 vol.% CW, 2 vol.% SA, and 1 vol.% EVA. PW and CW were selected to help with part ejection after mold filling, SA was used to promote the surfactant effect that strengthens chemical bonds between powder and binder, and EVA to produce a thickening effect necessary to control powder segregation.…”

Section: Binder Systemmentioning

confidence: 99%

“…There is no exact range for α STV in the literature since many parameters can affect the final value of the moldability index. It can be seen in the literature that researchers have found a wide range of α STV between 9000 and 300,000 for suitable feedstocks [36,105,116]. Some investigations have been done on the rheological properties of LPIM.…”

Section: Rheological Propertiesmentioning

confidence: 99%

“…Research groups have used LPIM to produce parts out of metals, ceramics, and carbides, including 316-L stainless steel [30], Inconel 718 superalloy [31], alumina [32], cemented tungsten carbide [33], and near-net-shape ceramic parts in the range of 100-10,000 units [34]. Current research focuses on developing experimental methods and numerical simulations to examine the impact of powder characteristics, injection parameters, and feedstock features on metal powder and binder segregation during injection molding [35][36][37]. Recent developments in LPIM can be attributed to the impressive growth rate of conventional PIM technology and the new requirements brought in by the automotive, medical, and aerospace sectors [38].…”

Section: Introductionmentioning

confidence: 99%

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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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Processability of High Metal and Ceramic Concentration Compounds

Hausnerová

Filip

2021

Encyclopedia of Materials: Composites

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Effect of Powder Shape and Size on Rheological, Thermal, and Segregation Properties of Low-Pressure Powder Injection Molding Feedstocks

Cited by 16 publications

References 36 publications

Rheological Behaviour of Highly Filled Materials for Injection Moulding and Additive Manufacturing: Effect of Particle Material and Loading

Rheological Behaviour of Highly Filled Materials for Injection Moulding and Additive Manufacturing: Effect of Particle Material and Loading

Research Progress on Low-Pressure Powder Injection Molding

Processability of High Metal and Ceramic Concentration Compounds

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