Surface adhesion between ceramic injection molding feedstocks and processing tools

Hausnerová, Berenika; Bleyan, Davit; Kašpárková, Věra; Pata, Vladimír

doi:10.1016/j.ceramint.2015.08.132

Cited by 23 publications

(17 citation statements)

References 18 publications

(20 reference statements)

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“…The measurement of the rheological behavior in smooth dies results in greater underestimated viscosity, however, as shown in the studies [13,14], due to lower shear rate gradients, slipping at the wall might positively affect the tendency of PIM feedstocks towards powder and binder separation. Figure 9 demonstrates that the values of slip velocities obtained for Al 2 O 3 powder in the smooth slit die are comparable with the slip velocities of ZrO 2 feedstock in the roughened slit die; the tendency of Al 2 O 3 feedstock to wall slip as a function of the die geometry and surface roughness is generally less pronounced than for ZrO 2 compound, although as we showed recently [31], their surface characteristics (surface energies) were fairly similar—44 and 47 J/m 2 for ZrO 2 and Al 2 O 3 , respectively.…”

Section: Resultssupporting

confidence: 75%

Online Rheometry Investigation of Flow/Slip Behavior of Powder Injection Molding Feedstocks

2019

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Wall slip in the flow of powder injection molding (PIM) compounds can be the cause of unrealistically low viscosity values, and can lead to a failure of flow simulation approaches. Regardless of its importance, it has been considered only scarcely in the rheological models applied to PIM materials. In this paper, an online extrusion rheometer equipped with rectangular slit dies was used to evaluate the slip velocity of commercial as well as in-house-prepared PIM feedstocks based on metallic and ceramic powders at close-to-processing conditions. The tested slit dies varied in their dimensions and surface roughness. The wall-slip effect was quantified using the Mooney analysis of slip velocities. The smaller gap height (1 mm) supported the wall-slip effect. It was shown that both the binder composition and the powder characteristic affect slip velocity. Slip velocity can be reduced by tailoring a powder particle size distribution towards smaller particle fractions. The thickness of the polymer layer formed at the channel wall is higher for water-soluble feedstocks, while in the case of the catalytic polyacetal feedstocks the effect of surface roughness was manifested through lower viscosity at smooth surfaces.

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Section: Resultssupporting

confidence: 75%

Online Rheometry Investigation of Flow/Slip Behavior of Powder Injection Molding Feedstocks

2019

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“…Functional prototype parts and tooling are manufactured directly from computer models [ 8 ]. CIM technology usually uses a binder system based on polyolefins and the waxes low density polyethylene (LDPE), poly(ethylene glycol) 6000 (PEG6000), paraffin wax (PW), carnauba wax (CW), Acrawax (AW), and stearic acid (SA), and the loading of the binder system varies from 14.5 to 15.8 wt% [ 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

Alumina Manufactured by Fused Filament Fabrication: A Comprehensive Study of Mechanical Properties and Porosity

et al. 2022

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This article deals with a comprehensive study of the processing and mechanical properties of the ceramic material Al2O3 on Fused Filament Fabrication technology (FFF). It describes the basic input analyses of the material, such as TGA, FTIR, and MVR. These analyses enabled the design and testing of process parameters for the 3D printing of parts. The article also presents the post-processes, including the technological parameters required to finalize parts made from this material, i.e., chemical debinding in acetone at elevated temperatures + thermal debinding and sintering. The microhardness was measured on the processed samples, depending on the density of the inner filling. The resulting hardness had an almost linear relationship between the percentage of filler (20–40–60–80–100%) and the resulting microhardness (1382–2428 HV10). Flexural strength was also measured on the test specimens with different degrees of internal filling (80–90–100%). However, inner filling do not affect the flexural strength (316.12–327.84–331.61 MPa). The relative density of the final parts was measured on a ZEISS METROTOM 1500 CT machine and reached 99.54%.

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“…Primary (backbone) binders for highly filled metal and ceramic powder feedstocks are mostly based on polyolefins (low-and high-density polyethylenes and polypropylene) [4][5][6]. For ceramic powders, water-soluble binders based on polyethylene glycol (PEG) steadily gain attention [7][8][9][10]. Lower molecular weight of PEG is usually recommended for PIM applications [11][12][13][14].…”

Section: Introductionmentioning

confidence: 99%

“…Recently, we showed that semicrystalline waxes such as carnauba wax (CW) and acrawax (AW) have a promising potential as binders for high powder loadings [7,9], and they could substitute the role of polyolefin backbone in PIM binder compositions [10]. According to the FTIR, calorimetry and contact angles analyses [7,15], AW have high values of polar component of surface energy and proved to have twice as strong interactions to PEG than CW. On the other hand, based on the contact angles analysis [7], CW may overtake the role of SA as a surfactant.…”

Section: Introductionmentioning

confidence: 99%

“…According to the FTIR, calorimetry and contact angles analyses [7,15], AW have high values of polar component of surface energy and proved to have twice as strong interactions to PEG than CW. On the other hand, based on the contact angles analysis [7], CW may overtake the role of SA as a surfactant. Furthermore, PEG can be easily debound in water, and CW is a renewable resource (Copernicia prunifera palm).…”

Section: Introductionmentioning

confidence: 99%

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Environmentally Efficient 316L Stainless Steel Feedstocks for Powder Injection Molding

Hausnerová

Novák

2020

Polymers

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In this study, environmentally convenient highly metal powder filled feedstocks intended for powder injection molding is presented. The composition of 60 vol % 316L stainless steel gas atomized powder feedstocks containing semicrystalline waxes: acrawax or carnauba wax and paraffin wax, combined with polyethylene glycol and modifier, was optimized to provide defect-free parts. Rheological as well as thermogravimetric analyses supported with scanning electron microscopy and metallography were employed to set up optimum conditions for molding, debinding and sintering. The performance of the novel feedstock was compared with currently available polyolefines-based materials, and results showed an efficiency enhancement due to the substantially lower (about 100 °C) mixing and molding temperatures as well as a reduction of debinding and sintering times at the simultaneous achievement of better mechanical properties in terms of elongation and tensile strength, in comparison to the mass production feedstock.

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Surface adhesion between ceramic injection molding feedstocks and processing tools

Cited by 23 publications

References 18 publications

Online Rheometry Investigation of Flow/Slip Behavior of Powder Injection Molding Feedstocks

Online Rheometry Investigation of Flow/Slip Behavior of Powder Injection Molding Feedstocks

Alumina Manufactured by Fused Filament Fabrication: A Comprehensive Study of Mechanical Properties and Porosity

Environmentally Efficient 316L Stainless Steel Feedstocks for Powder Injection Molding

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