METAL INJECTION

MOLDING

Presented by:- Kaushik A. Manek

SID:- 999 91 4538
 INDEX
 Introduction – Definition
 Process Steps
 Process in Detail
 MIM Advantages
 Comparison with other Techniques
 Machine-Mold Modifications
 MIM Limitations
 Developments in MIM Process
 Application
 References
 INTRODUCTION
 Metal Injection Molding (MIM)
– Also Known as Powder Injection Molding (PIM)
– Advanced metallurgical technology
 Integration of shape-making capability of
Plastic injection molding with material
flexibility of powder metallurgy.
 Definition
– Ultra-fine metal particles - Plastic binder
– Injection molded using conventional injection
molding machine (with little modification)
– Then, plastic binder is removed - Debinding
– Sintering
 INTRODUCTION (Cont..)
 History – MIM process
– 1st - Raymond Wiech – Parmatech Corp.

 Misconception of Process

Metal powder melts in the barrel

Metal particles act as a Filler
Similar to a glass and fiber
reinforcement
 MIM PROCESS STEPS
 Mixing - Material
 Injection Molding
 Debinding
 Sintering
Process Steps – in Detail
 PROCESS IN DETAIL
 MIXING
– 1st step in MIM
– Metal Powder + Binder = Homogeneous
Compound
– Very Crucial step – Time consuming
– If not mixed properly – problem in later
stages
– Different types of Mixing systems
 Twin Screw
Extruder

Z-Blade

Single Screw
Extruder

Plunger
Extruder

Double Planetary Twin Cam

Different Mixing Systems
 MIXING (Cont…)
 Selection Criteria - Binder
– Flow Characteristics
 Viscosity< 10 Pa-s
 Strong and rigid after cooling

– Powder Interaction
 Lowcontact angle and good adhesion
 Chemically Passive with metal powder
 MIXING (Cont…)
 Selection Criteria (Cont…)
– Debinding
 Non-corrosiveand non-toxic
 Low ash content and low metallic content

– Manufacturing
 Inexpensive

 Easily Available
 Safe and environmentally acceptable

 Non-hygroscopic without volatile

 Long shelf life

 High lubricity & High thermal conductivity

 Low thermal expansion of coefficient

 MIXING (Cont…)
 Examples of Binder system
45% Polystyrene 72% Polystyrene
45% Vegetable Oil 15% Polypropylene
5% Polypropylene 10% Polyethylene
5% Stearic Acid 3% Stearic Acid
67% Polypropylene 58% Polystyrene
22% Microcrystalline Wax 30% Mineral Oil
11% Stearic Acid 12% Vegetable Oil
25% Polypropylene 98% Aniline
75% Peanut Oil 2% Paraffin Wax
 MIXING (Cont…)
 Metal Used for MIM
– Fe, Ni, Co, Mn, Cu, Ti, Cr, C, Al etc...
 Examples of material available in
market
– Co-28Cr-4W-3Ni-1C = Stellite®
– Fe-16Cr-4Ni-4Cu = 17-4 PH Stainless
– Fe-29Ni-17Co = Kovar®
 INJECTION MOLDING
 Feedstock – Analogous to plastics injection
molding
 Part formed after injection called “GREEN
PART”
 Little modification in machine components
 Divided according to the material used
– Thermoplastic (same as conventional IM)
 Cold mold
 Generally PE and PP are used
INJECTION MOLDING (Cont…)

– Thermosetting system
 Larger cycle time
 Molded with high mechanical resistance in

green state.
 Epoxy and Polyester are used

– Thermo wax
 Binderbased on wax
 Lower viscosity than the other two system
 DEBINDING
 Process of removing binder
– Take long time
– Expensive stage
 Type of debinding – depends on the binder
material used within the part
 Debinding rate depends on following
factors:-
– Particle size
– Heating rate
– Particle packing density
– Debinding mechanism
– Solvent used
Debinding Reactor
 SINTERING
 Final stage in MIM process
 Debound part – heated to very high
temperature – specific period of time
 Metal particles bond to each other
 Process depends on the following factors:-
– Initial density
– Material used
– Particle size
– Temperature and Time
– Sintering atmosphere
 MIM Advantages
 Wide Latitude of part shape, sizes (0.1-250 g)
and design
 Ability to combine functions and eliminate sub-
assemblies
 Good dimensional control with close tolerances
 Good Mechanical Properties
 Net shape production, eliminating or minimizes
machining
 high production rates through use of multi-cavity tooling
 Wide range of available alloys, composites and
properties
MIM Advantages (cont…)
 Cost efficient for moderate-to-high production
volume
 Suitable for intricate and complex Geometries
 High Material Density and Strength
 Design Flexibility
 Produce Good Surface Finishes
 Attractive cost savings
 COMPARISON WITH
OTHER TECHNIQUES
 Significant cost saving by MIM over
the following competing Industries:-
 CNC machining
 Precision Machining
 Investment Casting
 Precision Casting
 Screw Machining
 Traditional Powder Metal
Cost Comparison Graph
 Comparison of Properties
with different Processes9
Powder
PARAMETERS MIM Casting Machining Stamping
Metallurgy
Density 98% 86% 98% 100% 100%

Tensile Strength High Low High High High

Surface Finish High Medium Medium High High

Size/Weight Low Low Medium Medium Low

Thin Wall Capability High Medium Med- Low High

High
Complexity High Low Medium High Low

Design Flexibility High Low Medium High Low

Production Quantity High High High High High

Range of Materials High High Low- High Medium

High
Cost Low Low Medium High Low
 Limitations of MIM
 Large part weight can not produced
 Wall thickness > 20 mm are uneconomical
 Residual stresses in molded part – leads to
warpage
 Difficult to control the injection pressure
 Higher tooling cost – screw, barrel, nozzle
– Screw, barrel and nozzle life – less compare to
used in conventional injection molding
 Machine-Mold
Modifications
 Feedstock analogous to IM
 Motor, pump, servo valve, accumulator –
specially designed
 Screw, cylinder, non-return valve, shut-off
valve – have been modified
 Less injection time
– Due to high thermal conduction
 Problem of jetting – solved by injection rate profile
 Maintain nozzle Temp. –to keep viscosity
minimum
 Machine-Mold
Modifications (cont…)

 Mold thoroughly hardened

 Ejectors – largest possible surface

area – for easy de-molding

 Cavities should be very well vented

 Temperature difference in cavities

must not exceed ±1.5 oC

Developments in Process

 Production of Large Parts

– In MIM, Debinding stage has many
problems
A long debinding time
 Oxidation of metal powder

– To overcome this problem

 first organic solvents
– Harmful for human body and environment
Production of Large Parts
(cont…)
– An extraction method using supercritical
CO2
 Remove binder in short time
 Time can be reduced to 1/50th

 Adequate for debinding of large parts

 Using this new binder

– Large parts can be produced soundly

– Production ability of MIM can be extended
Developments in Process (cont…)

 Low Pressure Technique

– Main advantages of low pressure IM
 Directly
in relation to that of high pressure
 Low consumption of energy

 Non-necessity of complex hydraulic system

 Low wear of mold

Developments in Process (cont…)

 Water Based Binder System

– Technique Developed by Honeywell
(PowderFlo®)
 Main advantages of water based
binder
 To reduce the debinding time
 Parts can be molded at low temperature and
pressure
 Ability to make large, thick parts more easily
 APPLICATIONS
 Fields of Application for MIM includes:-
– Automotive
– Watches and spectacles
– Locks and Keys
– In Jewellery Production
– Printer Components
– Hand tools hardware
– Aircraft and firearms
Automotive
                                 
                                                    
 REFERENCES
 Aparecido Carlos Goncalves, “Metallic Powder Injection
Molding using Low Pressure”, Journal of Materials
Processing Technology 118 (2001), pp 193-198.
 Dubridge T, “Metal Injection Molding: An Exciting new
Process for Moulders”, Antec ’93, New Orleans, 9th – 13th
May 1993, Vol.-III, pp 2738-42.
 Schumacher C, “Powder Injection Molding for Novel Part
Shapes”, Kunststoffe Plast Europe – ISSN- 0941-3596 –
citation- 89, No. 9, Sept. 1999, pp. 23-5.
 “Injection Molding Process Guide for PowderFloTM”,
AlliedSignal System Inc.
 Bader C, “Powder Injection Molding”, Kunststoffe Plast
Europe – ISSN- 0941-3596 – citation- 85, No. 4, April 1995,
pp. 16-7.
REFERENCES (Cont…)
 T. Shimizu, Kitazima, Nose, S. Fuchizawa, T. Sano,
“Production of Large size parts by MIM process”, Journal of
Materials Processing Technology 119 (2001), pp 199-202.
 Peter Mapleston, “Metal Powder Technology is enhanced
with Water-based Binder System”, Modern Plastics, Sep
2000, v77, i9 pp 39.
 Robert E. Irving, “Starting small, Metal Injection Molding is
Facing a rapidly expanding Demand”, Metalworking News,
Dec 7, 1987, v14, n660 pp 31(2).
 “MIM Benefits and Comparisons with other Processes”, Feb
27, 2002, [Link]
 “MIM Advantages”, March 20, 2002, [Link]
.com/[Link].