Handbook of metal injection molding / edited by Donald F. Heaney.

Format:

Book

Contributor:

Heaney, Donald F., editor.

Language:

English

Subjects (All):

Injection molding of metals.

Physical Description:

1 online resource (652 pages)

Edition:

2nd ed.

Place of Publication:

Duxford, England ; Cambridge, Massachusetts ; Kidlington, England : Woodhead Publishing, [2019]

Summary:

Metal injection molding combines the most useful characteristics of powder metallurgy and plastic injection molding to facilitate the production of small, complex-shaped metal components with outstanding mechanical properties. Handbook of Metal Injection Molding, Second Edition provides an authoritative guide to this important technology and its applications.Building upon the success of the first edition, this new edition includes the latest developments in the field and expands upon specific processing technologies. Part one discusses the fundamentals of the metal injection molding process with chapters on topics such as component design, important powder characteristics, compound manufacture, tooling design, molding optimization, debinding, and sintering. Part two provides a detailed review of quality issues, including feedstock characterisation, modeling and simulation, methods to qualify a MIM process, common defects and carbon content control. Special metal injection molding processes are the focus of part three, which provides comprehensive coverage of micro components, two material/two color structures, and porous metal techniques. Finally, part four explores metal injection molding of particular materials, and has been expanded to include super alloys and precious metals.With its distinguished editor and expert team of international contributors, the Handbook of Metal Injection Molding is an essential guide for all those involved in the high-volume manufacture of small precision parts, across a wide range of high-tech industries such as microelectronics, biomedical and aerospace engineering.- Provides an authoritative guide to metal injection molding and its applications- Discusses the fundamentals of the metal injection molding processes and covers topics such as component design, important powder characteristics, compound manufacture, tooling design, molding optimization, debinding and sintering- Comprehensively examines quality issues, such as feedstock characterization, modeling and simulation, common defects and carbon content control

Contents:

Front Cover

Handbook of Metal Injection Molding

Copyright

Contents

Contributors

Chapter 1: Metal powder injection molding (MIM): Key trends and markets

1.1. Introduction and background

1.2. History of success

1.3. Industry structure

1.4. Statistical highlights

1.5. Industry shifts

1.6. Sales situation

1.7. Market statistics

1.8. Metal PIM market by region

1.9. Metal PIM market by application

1.10. Market opportunities

1.11. Production sophistication

1.12. Conclusion

Further reading

Part One: Processing

Chapter 2: Designing for metal injection molding (MIM)

2.1. Introduction

2.2. Available materials and properties

2.3. Dimensional capability

2.4. Surface finish

2.5. Tooling artifacts

2.5.1. Parting line

2.5.2. Ejector pin marks

2.5.3. Gate locations

2.6. Design considerations

2.6.1. Flats for sintering

2.6.2. Wall thickness

2.6.3. Draft

2.6.4. Threads

2.6.5. Ribs and webs

2.6.6. Radii

2.6.7. Bosses

2.6.8. Undercuts

2.6.9. Decorative features

Chapter 3: Powders for metal injection molding (MIM)

3.1. Introduction

3.2. Ideal MIM powder characteristics

3.2.1. Size

3.2.2. Size distribution

3.2.3. Shape

3.3. Characterizing MIM powders

3.3.1. Pycnometer density (MPIF 63, ASTM D 2638, ASTM D 4892)

3.3.2. Apparent density (MPIF 28 and 48, ASTM B 417 and B 703, ISO 3923-1 and 3953)

3.3.3. Tap density (MPIF 46, ASTM B 527, ISO 3953)

3.3.4. Particle size distribution (ASTM B 822-10, ISO 13320-1)

3.4. Different MIM powder fabrication techniques

3.4.1. Gas atomization

3.4.2. Water atomization

3.4.3. Thermal decomposition

3.4.4. Chemical reduction

3.5. Different alloying methods

3.5.1. Elemental method

3.5.2. Prealloy method

3.5.3. Master alloy method

References.

Chapter 4: Powder-binder formulation and compound manufacture in metal injection molding (MIM)

4.1. Introduction: The role of binders

4.2. Binder chemistry and constituents

4.2.1. Binder chemistry

4.2.2. Binder constituents

4.3. Binder and powder properties and their effects on feedstock

4.3.1. Flow: Rheology as a function of shear rate, temperature, and particle attributes

Effect of shear rate

Effect of temperature

Effect of particle characteristics

4.3.2. Solidification: Thermal conductivity, heat capacity

4.3.3. Shrinkage and warpage: Density, PVT parameters, and modulus

Density

PVT parameters

Modulus

4.3.4. Removal: Solubility, thermal degradation

Wicking

Solvent extraction

Thermal debinding

Strength model

Defect formation

Carbon contamination

Distortion

4.4. Mixing technologies

4.5. Case studies: Lab scale and commercial formulations

References

Chapter 5: Tooling for metal injection molding (MIM)

5.1. Introduction

5.2. General design and function of injection molding machines

5.3. Elements of the tool set

5.4. Tool design options

5.4.1. Mold materials

5.4.2. Oversize design

5.4.3. Gating options and venting

5.4.4. Undercut design

5.5. Special features and instrumentation

5.6. Supporting software and economic aspects

Chapter 6: Molding of components in metal injection molding (MIM)

6.1. Introduction

6.2. Injection molding equipment

6.2.1. Conventional injection molding machines

6.2.2. Microinjection molding machines

6.2.3. The mold

6.3. Auxiliary equipment

6.3.1. Material drying

6.3.2. Mold temperature controllers

6.3.3. Granulators

6.3.4. Part removal

6.4. Injection molding process

6.4.1. Overview

6.4.2. Molding parameters

Mold and melt temperature.

Injection speed

Switchover point and method

Hold pressure and time

Cool time

6.4.3. Shrinkage

6.4.4. PVT effect

6.4.5. Anisotropic shrinkage

6.5. Common defects in MIM

Chapter 7: Debinding and sintering of metal injection molding (MIM) components

7.1. Introduction

7.1.1. Binder systems

7.1.2. The first MIM systems

7.2. Primary debinding

7.2.1. Solvent debinding of wax-based systems

7.2.2. Supercritical solvent debinding

7.2.3. Catalytic debinding of Catamold feedstock

7.2.4. Debinding of water-soluble systems

7.2.5. Primary debinding guidelines

7.3. Secondary debinding

7.3.1. Incomplete binder removal

7.4. Sintering

7.4.1. Sintering definitions

7.4.2. Sintering theories

7.4.3. Mass transport mechanisms

7.4.4. Stages of sintering

7.4.5. Sintering practices

7.4.6. Sintering in the presence of a liquid phase

7.4.7. Sintering in MIM

7.4.8. Effect of powder size and surface area

7.4.9. Sintering atmospheres

7.4.10. Sintering results

7.5. MIM materials

7.5.1. Effect of reactivity of materials

Precious metals

Metals whose oxides are easily reducible

Carbon steels

High alloyed steels containing carbon

Corrosion resistant low carbon steels

Tungsten alloys

Titanium and its alloys

High-temperature alloys

Other materials

7.5.2. Powder availability

7.6. Settering

7.7. MIM furnaces

7.7.1. Evolution of MIM furnaces

7.7.2. Continuous furnaces

7.7.3. Batch furnaces

7.7.4. Comparing batch and continuous furnaces

7.8. Furnace profiles

7.9. Summary

Acknowledgments

Chapter 8: Secondaries for metal injection molding (MIM)

8.1. Introduction

8.2. Operations to improve dimensional control

8.2.1. Mechanical deformation (sizing)

8.2.2. Machining.

8.3. Operations to enhance mechanical properties

8.4. Operations to improve appearance and surface properties

8.5. Operations to reduce tooling cost and enhance applications

8.6. Resume-Outlook

Chapter 9: Hot isostatic pressing (HIP) of metal injection molding (MIM)

9.1. Introduction

9.2. The HIP process

9.3. Benefits of the HIP process

9.4. Issues with the HIP process

9.5. Example HIP processes conditions

9.6. Conclusion

Part Two: Quality issues

Chapter 10: Characterization of feedstock in metal injection molding (MIM)

10.1. Introduction

10.2. Rheology

10.3. Thermal analysis

10.4. Thermal conductivity

10.5. Pressure-volume-temperature

10.6. Conclusions

Chapter 11: Modeling and simulation of metal injection molding (MIM)

11.1. Modeling and simulation of the mixing process

11.1.1. Modeling

11.1.2. Numerical methods

Finite element formulation

Particle-tracking method

11.1.3. Applications

Mixer and mixing materials

Working principle of the Kenics mixer based on flow characteristics

Mixing analysis

11.2. Modeling and simulation of the injection molding process

11.2.1. Theoretical background and governing equations

Filling stage

Packing stage

Cooling stage

11.2.2. Numerical simulation

Filling and packing analysis

Cooling analysis

Coupled analysis between filling, packing, and cooling stages

11.2.3. Experimental-Material properties and verification

Material properties for the filling stage

Material properties for the packing stage

Material properties for the cooling stage

Verification

11.2.4. Applications

Basic capability-Short shot, flash, weld line, air vent, and other features

Optimization of filling time.

11.3. Modeling and simulation of the thermal debinding process

11.3.1. Theoretical background and governing equations

MDC for a single reaction step

Calculation of apparent activation energy

MDC for multireaction steps

11.3.2. Applications

Calculation of activation energy

MDC for single reaction-step decomposition

MDC for multireaction step decomposition

Effect of metal powders

Weight-temperature-time plot

11.4. Modeling and simulation of the sintering process

11.4.1. Theoretical background and governing equations

Constitutive relation during sintering

Numerical simulation

11.4.2. Experimental determination of material properties and simulation verification

11.4.3. Applications

Gravitational distorting in sintering

Sintering optimization

11.5. Conclusion

Chapter 12: Common defects in metal injection molding (MIM)

12.1. Introduction

12.2. Feedstock

12.2.1. Feedstock uniformity

12.2.2. Recycled feedstock

12.3. Molding

12.3.1. Flash

12.3.2. Residual stress

12.3.3. Binder/powder separation

12.3.4. Other defects

12.4. Debinding

12.4.1. Solvent debinding

12.4.2. Thermal debinding

12.4.3. Binder residues

12.5. Sintering

12.5.1. Appearance and discoloration

12.5.2. Dimensional control and distortion

12.6. Conclusion

Chapter 13: Qualification of metal injection molding (MIM)

13.1. Introduction

13.2. The metal injection molding process

13.3. Product qualification method

13.4. MIM prototype methodology

13.4.1. Material selection

13.4.2. Prototype production

13.5. Process control

13.6. Understanding of control parameters

13.6.1. Powder characteristics

Chemistry

Powder size and size distribution

13.6.2. Feedstock behavior

Density (pycnometer, Archimedes)

Feedstock viscosity.

13.6.3. Injection molding.

Notes:

Includes index.

Description based on print version record.

ISBN:

0-08-102809-1

0-08-102153-4

0-08-102152-6