Low-Pressure Injection Molding of Alumina Ceramics Using a Carnauba Wax Binder: Preliminary Results

Nogueira, Ricardo Emílio Ferreira Quevedo; Bezerra, Alexandre Campos; Santos, Francisco Claudioberto dos; Sousa, Maria Rosimar de; Acchar, Wilson

doi:10.4028/www.scientific.net/kem.189-191.67

Cited by 11 publications

(5 citation statements)

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“…Normally, the size of the powder used for metal injection molding purpose ranges between 4 mm to 20 mm. Although in some studies this range has been narrowed down to 2 mm to 8 mm [20]. In this study low alloy steel 4605 powder manufactured using gas atomization technique supplied by Unifine Company is used.…”

Section: Experimental Procedures 21 Materialsmentioning

confidence: 99%

“…In few studies, carnauba wax has been used in large volume, as the basic component of the binder system. For example, the effect of carnauba wax percentage in feedstock on the injection pressure of Alumina ceramic powder feedstock was investigated where 91 wt.%, 92 wt.% and 94 wt.% of carnauba wax as the base for the binder was used and concluded that the higher amount of carnauba wax results in lower viscosity of the feedstock as well as the injection pressure [19].…”

Section: Introductionmentioning

confidence: 99%

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Effect of carnauba wax as a part of feedstock on the mechanical behavior of a part made of 4605 low alloy steel powder using metal injection molding

Momeni

Alaei

Askari

et al. 2019

Materialwissenschaft Werkst

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Metal injection molding is a growing technology for producing complex metallic components. Preparation of feedstock for metal injection molding is a very crucial step during this process. This is because the deficiencies in quality of the feedstock once made, cannot be corrected by subsequent processing steps. One of the challenges in producing the feedstock is its formulation. In this study, the effect of the percentage of carnauba wax along with other binder constituents of paraffin wax, polypropylene and stearic acid is investigated on the density, strength, hardness and rheological behavior of a part, made of 4605 low alloy steel powder using metal injection molding process. For this reason, six binder systems including paraffin wax, polypropylene and stearic acid having different percentages of carnauba wax have been produced. After preparation of the samples, tensile testing, Vickers hardness test, density and rheological behavior of the samples have been measured and compared. The results show that carnauba wax as a part of feedstock, has a positive effect on the strength and density while negative effect on the hardness of the final sintered part. Also with the increase in the percentage of the carnauba wax inside the polymer binder, the viscosity of the feedstock was reduced significantly.

show abstract

Section: Experimental Procedures 21 Materialsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of carnauba wax as a part of feedstock on the mechanical behavior of a part made of 4605 low alloy steel powder using metal injection molding

Momeni

Alaei

Askari

et al. 2019

Materialwissenschaft Werkst

View full text Add to dashboard Cite

show abstract

“…However, the study concluded that a process needed to be developed specifically to better understand the interaction between injection variables and to mitigate problems appearing during debinding. Almost simultaneously, Quevedo Nogueira et al [13] demonstrated that carnauba wax could be successfully used as an organic vehicle in the formulation of low-viscosity ceramic-based feedstock and injected at a pressure as low as 0.6 MPa when blended with low-density polyethylene and stearic acid. Ten years later, in a very comprehensive study, Piotter et al [14] confirmed the ability of the LPIM process to produce microscopic parts (also known as micro-PIM) from ceramic-as well as metallic-based feedstocks.…”

Section: Introductionmentioning

confidence: 99%

Injection Flow Rate Threshold Preventing Atypical In-Cavity Pressure during Low-Pressure Powder Injection Molding

Arès,

Delbergue,

Demers

2023

Powders

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Controlling injection parameters is paramount when it comes to producing high-quality green parts using powder injection molding. This work combines experimental and numerical approaches to study the impact of injection parameters on mold in-cavity pressure and on the overall quality of green parts produced by low-pressure powder injection molding. The properties of two low-viscosity feedstocks (formulated from a water-atomized stainless-steel powder and wax-based binder system) were measured and implemented in an Autodesk Moldflow numerical model to quantify the molding pressures, which were finally validated using experimental real-scale injections. The results confirmed that an increase in mold temperature, an increase in feedstock temperature, and a decrease in solid loading decrease the mold in-cavity pressure, which was correlated with the feedstock viscosity. As a key result, real-scale injections confirmed that a minimum flow rate was required to avoid atypical high in-cavity pressure leading to several visual defects such as weld lines, flow marks, cracks, sinks, and incomplete filling. Due to differences in its thermal transfer properties, this flow rate threshold value decreases as the feedstock solid loading increases. For injection speeds higher than this value, the injection pressure measured experimentally was linearly correlated with the injection flow rate.

show abstract

Section: Introductionmentioning

confidence: 99%

Injection Flow Rate Threshold Preventing Atypical In-Cavity Pressure during Low-Pressure Powder Injection Molding

Arès,

Delbergue,

Demers

2023

Preprint

View full text Add to dashboard Cite

Controlling injection parameters is paramount when it comes to producing high-quality green parts using powder injection molding. This work combines experimental and numerical approaches to study the impact of injection parameters on mold in-cavity pressure and on the overall quality of green parts produced by low-pressure powder injection molding. The properties of two low-viscosity feedstocks (formulated from a water-atomized stainless-steel powder and wax-based binder system) were measured and implemented in an Autodesk Moldflow numerical model to quantify the molding pressures, which were finally validated using experimental real-scale injections. The results confirmed that an increase in mold temperature, an increase in feedstock temperature, and a decrease in solid loading decrease the mold in-cavity pressure, which was correlated with the feedstock viscosity. As a key result, real-scale injections confirmed that a minimum flow rate was required to avoid atypical high in-cavity pressure leading in several visual defects such as weld lines, flow marks, cracks, sinks, and incomplete filling. Due to differences in its thermal transfer properties, this flow rate threshold value decreases as the feedstock solid loading increases. For injection speeds higher than this value, the injection pressure measured experimentally was linearly correlated with the injection flow rate.

show abstract

Low-Pressure Injection Molding of Alumina Ceramics Using a Carnauba Wax Binder: Preliminary Results

Cited by 11 publications

References 0 publications

Effect of carnauba wax as a part of feedstock on the mechanical behavior of a part made of 4605 low alloy steel powder using metal injection molding

Effect of carnauba wax as a part of feedstock on the mechanical behavior of a part made of 4605 low alloy steel powder using metal injection molding

Injection Flow Rate Threshold Preventing Atypical In-Cavity Pressure during Low-Pressure Powder Injection Molding

Injection Flow Rate Threshold Preventing Atypical In-Cavity Pressure during Low-Pressure Powder Injection Molding

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