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Managing Director and Editor For the metal, ceramic and carbide injection moulding industries Nick Williams Tel: +44 (0)1743 454991 Fax: +44 (0)1743 469909 Email: [email protected]

Publishing Director Paul Whittaker Tel: +44 (0)1743 454992 Fax: +44 (0)1743 469909 Email: [email protected]

Consulting Editors Professor Randall M. German The PIM community Associate Dean of Engineering, Professor of Mechanical Engineering, San Diego State University, USA prepares to meet in Italy Dr Yoshiyuki Kato Kato Professional Engineer Office, Yokahama, Japan The forthcoming PM2010 World Congress, to be held in Florence, Dr Professor Frank Petzoldt 10-14 October, is set to be the major event of the year for the Deputy Director, Fraunhofer IFAM, Bremen, Germany international powder injection moulding community. PIM technology Bernard Williams appears to play an ever more central role at international PM events, Consultant, Shrewsbury, UK and this world congress is no exception. A packed exhibition hall Advertising showcases the latest powders, feedstock and processing equipment Jon Craxford, Advertising Manager for PIM, whilst eight conference sessions and a special interest Tel: +44 (0) 207 1939 749 seminar are dedicated to technological developments. Fax: +44 (0) 1242 291 482 E-mail: [email protected] The world congress will certainly present a valuable opportunity for Subscriptions customers and suppliers to meet and discuss the challenges facing Powder Injection Moulding International is published the industry. High on the agenda of many MIM part producers will be on a quarterly basis. The annual subscription concerns about availability of powder supply. Rumours suggest that charge for four issues is £95.00 including shipping. Rates in € and US$ are available on application. delivery times for atomised powders are getting longer due to high levels of demand, and there will inevitably be discussions relating Accuracy of contents to the need for additional capacity from the established players. Whilst every effort has been made to ensure the Such concerns, of course, open up opportunities for new companies accuracy of the information in this publication, the publisher accepts no responsibility for errors looking to move into this lucrative market. or omissions or for any consequences arising /NTHELEADINGEDGEOF there from. Inovar Communications Ltd cannot Italy is home to a number of major producers of PM products, from be held responsible for views or claims expressed hardmetals and diamond tools to standard PM components. The by contributors or advertisers, which are not country’s MIM industry, however, is less well known. In this issue we necessarily those of the publisher. report on visits to three Italian MIM producers and discover some METALPOWDERMANUFACTURE Advertisements unique applications and innovations (page 31). Although all advertising material is expected to conform to ethical standards, inclusion in this We also report on how GKN Sinter Metals, traditionally a MIM publication does not constitute a guarantee or endorsement of the quality or value of such product producer focused on the automotive industry, is looking to the or of the claims made by its manufacturer. non-automotive sector for growth opportunities (page 45). Our With over 35 years’ experience in gas atomisation, Sandvik Osprey offers “back-to-basics” series continues with a review of the handling and Reproduction, storage and usage testing of green parts (page 50), and Plansee proposes improving the world’s widest range of high quality, spherical metal powders for use in Single photocopies of articles may be made for the efficiency of MIM furnaces through new materials and design personal use in accordance with national copyright Metal Injection Moulding. Our products are used in an increasingly laws. Permission of the publisher and payment of solutions (page 55). diverse range of applications across a number of global industries fees may be required for all other photocopying. including automotive, consumer electronics and medical. Nick Williams All rights reserved. Except as outlined above, no Managing Director and Editor part of this publication may be reproduced, stored in Using gas atomised powders can enhance your productivity and a retrieval system, or transmitted in any form or by any means, electronic, photocopying or otherwise, profitability, so contact our technical sales team today for more information. without prior permission of the publisher and copyright owner.

Design and production Cover image Inovar Communications Ltd View of a Gitzo brand ‘Titanium Traveller’ photographic tripod, featuring a large titanium Printed by Cambrian Printers, Aberystwyth, United Kingdom MIM body produced by Mimest Spa, Italy. Photo courtesy Lino Manfrotto + Co. SpA 3ANDVIK/SPREY,IMITED ISSN 1753-1497 -ILLAND2OAD.EATH3!.*5+0HONE  &AX   Vol. 4, No. 3 September 2010 Vol. 4 No. 3 September 2010 Powder Injection Moulding International  WWWSMTSANDVIKCOMOSPREYE MAILPOWDERSOSPREY SANDVIKCOM © 2010 Inovar Communications Ltd.

cover spread September 2010.indd2 2 September 2010 front section new1 1 9/10/20109/9/2010 12:27:06 4:56:36 PM PM September 2010

Come and visit us on our standthth PM 2010 thth-14 PM 2010Oct. 10 Florence (Italy)Stand – 43

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In this issue

31 MIM in Italy: A review of early development 55 Higher efficiency MIM furnaces through and current activity new materials and design solutions To coincide with Italy’s hosting of the 2010 Powder The metal injection moulding process can be extremely Metallurgy World Congress and Exhibition in Florence, demanding on sintering furnaces and related fixtures October 10-14, we present the following review of the and supports. High temperatures, combined with current status of metal injection moulding in Italy. In the presence of binder systems, can lead to a rapid addition to this introduction, reports are presented on deterioration in furnace performance and efficiency. the MIM activities of three representative Italian part Dr. Bernd Kleinpass, from PLANSEE Metall GmbH in producers: Mimest, MIMITALIA and Metrocast Italiana. Austria, explores some of the main problems and the solutions that are now available. 45 All eyes on Non-Automotive: GKN Sinter Metals explores the wider opportunities for MIM Technical papers The term ‘non-automotive’ remains a closed book for many of the world’s larger MIM producers, particularly 60 Titanium parts by powder injection

those located in Europe where the automotive industry moulding of TiH2-based feedstocks was quick to embrace MIM technology. GKN Sinter E. Carreño-Morelli, W. Krstev, B. Romeira, M. Metals is one such producer that is now re-evaluating Rodriguez-Arbaizar, H. Girard, J.-E. Bidaux, the potential of the non-automotive market. In the S. Zachmann following report, the company presents an insight into the opportunities ahead and explains, based on its 64 Properties of SiC and AlN feedstocks for own experiences, what it believes is important when the powder injection moulding of thermal dealing with non-automotive customers. management devices V. P. Onbattuvelli, S. Vallury, T. McCabe, S. J. Park, 50 Back to basics: from the injection S. V. Atre moulding machine to the debinding oven Raw materials undergo several transformations during the metal injection moulding process, from Regular features powder through to feedstock, the production of the green compact, debinding and finally sintering. In this latest part of our back-to-basics series, Dr 4 Industry news Georg Schlieper focuses on green compacts and the 59 Global PIM patents methods used to characterise their properties, as well as green part processing and handling. 72 Events guide, Advertisers’ index

 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September 2010 front section new2 2 9/10/2010 12:27:07 PM September 2010 front section new3 3 9/10/2010 12:27:21 PM Industry News

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Sandvik Osprey wins UK export award for continuous export growth

Sandvik Osprey Ltd, part of the global space, general engineering and Sandvik AB Group, has recently consumer goods. announced that it is the proud recipient Sandvik Osprey Ltd is head-quar- of a Queen’s Award for Enterprise 2010 tered in Neath, UK where manufac- in the category International Trade. turing operations are located and This prestigious award recognises products are distributed globally via the Company’s sustained achieve- local Sandvik Sales Units. ment in continuously growing export “It is very pleasing to have won this performance over a six year period. The award” commented Managing Director, 'VSOBDFT
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September 2010 front section new4 4 9/10/2010 12:27:28 PM September 2010 front section new5 5 9/10/2010 12:27:28 PM PIM_International_216x313_2010.i1 1 08.07.2010 12:07:23 Industry News

Catamold® Global Powder Metallurgy Production of PM Parts and Bearings in Asia Imagination is the only limit! markets rebound in first half of 2010 Following several years of declining and transmissions shipments of Powder Metallurgy (PM) introduced by GM parts, mainly due to deteriorating and Ford. Metal production of light vehicles and cars Injection Moulding in North America, the PM industry (MIM) was reported returned to a growth track in the first to be bucking the [ Catamold® – Inject your ideas ] half of 2010, reported Michael Lutheran downward trend (Royal Metal Powders Inc), president of in N. America last the Metal Powder Industries Federation year thanks to the (MPIF) at the 2010 International PM growing firearms Conference in Florida, June 27-30. and medical Fig. 1 Production of PM parts and bearings (courtesy Asian Lutheran stated that iron powder markets, said Powder Metallurgy Association, APMA) shipments in N. America had increased Lutheran. by 29% in the second half of 2009 but A similar picture emerged in Asia Association (EPMA) reported at its still declined by 25% for the whole year where the Asian Powder Metallurgy General Assembly held in Brussels in to reach 244,839 short tonnes – a level Association (APMA) reported that April that ferrous powder shipments not seen since the early 1990s. First Japan’s ferrous PM production fell fell by 29.1% to 125,203 mt in 2009 quarter 2010 iron powder shipments by 33.4% to 72,221 metric tonnes in despite a strong recovery in shipments soared by 64% - compared to record 2009 (Fig. 1). However, China, Korea, in the second half of the year, when car low levels in the same period of 2009 and India managed to stay in positive scrappage schemes were introduced - thanks to a recovery in demand from territory with China’s PM production in a number of EU countries. The the car sector. Lutheran said that there overtaking Japan for the first time EPMA reported an 84% increase in iron was optimism for the future of PM in with reported output of 95,950 mt for powder shipments in the first quarter the automotive sector with PM parts ferrous and non-ferrous PM parts. of 2010 compared with the same period finding applications in new engines The European Powder Metallurgy last year.

BASF SE GBU Carbonyl Iron Powder and Metal Systems CIM Zirconia eyed for Powder Injection Molding G-CA/MI – J513 implantable pulse generators 67056 Ludwigshafen, Germany Implantable pulse generators (IPGs) are central to neuro- Phone: +49 621 60 52835 modulation devices which deliver electrical stimulation to E-mail: [email protected] the nervous system in the form of very small pulses from Internet: www.basf.de/catamold a micro-electronic device implanted in the body. Most IPGs are currently made from titanium but work on improving the feedthrough, which is a key mechanical structure in the device providing the electrical connection for the wires transmitting and receiving the electrical signals, has seen the development of thin-walled IPGs produced by ceramic injection moulding of zirconia. According to a report in the on-line Medical Design Technology magazine (June 30, 2010), Morgan Technical Discover the amazing possibilities of metal and ceramic components Ceramics of Stourport, UK, is said to be in the early stages of transforming powder to components ® manufacturing using Power Injection Molding with Catamold and BASF. developing a thin-wall implantable housing made from CIM With Catamold®, conventional injection molding machines can be used to zirconia for use in migraine and cluster headache treatment. produce geometrically demanding components economically. You can do The CIM ceramic is then brazed and hermetically injectioninjection moldingmolding ofof metalmetal andand ceramicceramic feedstockfeedstock asas easilyeasily asas plastic.plastic. sealed to the feedthrough. The injection moulded zirconia And this opens up new means of producing complex components that is biocompatible and complies with ISO 13356 implants provide economic and technical benefi ts in sectors ranging from Automotive, for surgery. The CIM zirconia casing is also reported to be Consumer Products, and Mechanical Engineering to Medical Products and stronger than titanium allowing for a mechanically robust Communications/Electronics. structure in a smaller sized housing. Other benefits include the transparency of zirconia to ® Take advantage of the new diversity in Powder Injection Molding with Catamold . radiofrequency energy allowing signals to pass through Get in touch with us – we’ll be glad to help you on the road to success. the wall of the device and possible charging, plus zirconia is inherently insulating allowing electrical wires to be ®= registered trademark of BASF SE placed closer together than a metal flanged feedthrough brazed into a metal housing.

 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September892_Catamold_Anzeige_210x297.indd 2010 front section new6 6 1 21.08.20089/10/2010 16:43:11 12:27:29 Uhr PM September 2010 front section new7 7 9/10/2010 12:27:32 PM Industry News

Polymer Technologies, Inc. continues to aerospace clients can be re-assured that the MIM parts and engineering target the MIM aerospace market, and services provided will continue to meet all the technical requirements and passes re-certification audit of its SAE process specifications to the most rigid AS9100B & ISO 9001:2008 of standards. Polymer Technologies operates out Polymer Technologies Inc., based Further, the re-certification is a of a 150,000 sq foot state-of-the-art in Clifton, New Jersey, USA, has reflection of the company’s ongoing manufacturing and research centre announced that it has passed the efforts to further advance the expan- in Clifton, New Jersey. The company rigorous re-certification audit renewing sion and acceptability of its Metal offers a variety of engineering the company’s existing Aerospace Injection Moulding (MIM) technology services such as material selection, Quality Standard SAE AS9100B certi- for use in aircraft parts and engine part and mould design, MoldFlow™ fication. As stringent as the original components. MIM offers reduced analysis as well as low and high volume certification audit, this re-certification part weights, increased throughput production. indicates that Polymer Technologies and significant cost reductions when More information on Polymer continues to meet and exceed the compared to competing technolo- Technologies Inc. and metal injection requirements of ISO 9001:2008 as well gies such as investment casting and moulding is available at the company as AS 9100B. machining. Now, with the AS9100 website. Polymer Technologies is a plastic re-certification, Polymer Technologies’ www.polymertechnologies.com and metal injection moulding company that has been providing advanced injection moulding services to global leaders in the aerospace, healthcare, commercial and military industries for over 20 years. “We are pleased to have passed the re-certification audit,” said Polymer Technologies Vice President, Neal Goldenberg. ”This achievement is a true testament to the hard-work and dedication of the Polymer Technologies team and our ongoing commitment to providing superior customer service and high-quality products. This is a crucial stepping stone toward our next goal of ISO 13485 certification to more fully support the medical industry.” MIM aerospace components manufactured by Polymer Technologies Inc

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September 2010 front section new8 8 9/10/2010 12:27:35 PM September 2010 front section new9 9 9/10/2010 12:27:37 PM Industry News

11 00 00 11 00 00

99 55 99 55 MIM helps shots fly far and 77 55 77 55 land soft 22 55 22 55 Metal injection moulding (MIM) has over the past decade

found a number of applications in sporting equipment such 55 55 as golf clubs, darts, fishing weights, arrows and sporting guns. In golf putters introduced by Never Compromise 00 00 (now part of Cleveland Golf) in the late 1990s, high density MIM tungsten weights were placed on the heel and toe of the putter head. This selective placement of MIM weights helps to control torque and aids in the relocation of the centre of gravity during ball strike. Earlier this year Callaway Golf introduced MIM tungsten-based weights in its FT-iZ Hybrid golf club using a graphite shaft incorporating what the company calls advanced ‘Fusion Technology’. The larger, high MOI clubheads combine a stainless steel body and sole with injection moulded high density weights to maximise perim- eter weighting which helps to produce strong trajectories that ‘fly farther and land softer’, states Callaway. Golf testers concur that these new hybrids are reliable performers with consistent distance and direction with most shots holding the target line. The potential of MIM titanium has also been explored in recent years Callaway’s FT-iZ Hybrid golf club uses for use in other high-end MIM tungsten-based weights golfing equipment. New on-line search facility for PM industry database The International Powder Metal- lurgy Directory’s website, www. ipmd.net has recently been relaunched with a new online search facility. This upgraded facility makes it significantly easier for users to find suppliers and producers of specific PM and MIM products, powders, feedstocks and production equipment. Paul Whittaker, Publishing Director, stated, “This new 11 00 00 11 00 00 streamlined search interface makes searching the contents of the IPMD 99 55 99 55 much faster. With over 4800 organi- sations in the database, users can 77 55 77 55 now find suppliers or customers in an instant. Around 200 specific products codes allow searches to be 22 55 22 55 refined to specific product types”. www.ipmd.net 55 55

00 00 0 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September 2010 front section new10 10 9/10/2010 12:27:41 PM September 2010 front section new11 11 9/10/2010 12:27:42 PM Industry News Industry News

PIM in weighting applications Cost saving bone-fracture and frangible ammunition fixation plates by MIM

Ecomass Technologies based in Austin, Texas, USA, has Dr Mohd Afian Omar, from the SIRIM Berhad research developed tungsten-based Ecomass Compounds which the centre in Malaysia, reports that a cost effective method of company states can be injection moulded using conven- producing fracture fixation plates has been developed using tional moulding equipment for a variety of applications. the metal injection moulding process (MIM). Examples given by the company include injection moulded Fracture Fixation Plates are devices used to stabilise a balancing weights in top of the range golf clubs, and fractured bone, enabling fast healing and a quicker return frangible projectiles for small calibre rifles and handguns. to mobility for the patient. Wires, pins, screws, plates, nails Ecomass states that the balancing weights used in golf and plates are some of the internal fixation devices generi- clubs can be produced in increments of 1 gram and allows cally referred to as fracture fixation devices. The fracture the shaft and club head in woods, irons and wedges to be fixation plates have been in use since the 1950s and they are perfectly balanced. Additionally, the polymer selected for mostly made of stainless steel and occasionally, less strong these compounds is said to dampen the vibration trans- but biologically superior and more elastic titanium fixation mitted up the shaft. implants. The company also reports that the Winchester division Conventionally, fracture fixation plates are made by of Olin Corp. has selected Ecomass Compounds as the casting, forging or machining. Despite having been in material for the 5.56 mm frangible projectiles in its Ranger use for decades, the conventional method of production line of non-toxic frangible ammunition. The projectiles are has several drawbacks, thus the need for improvement. either based on copper or tungsten filled compounds and The primary concern has been the risk of corrosion of are used for military and law enforcement training. This the implants caused by the inhomogenity in cast parts. avoids the toxicity, clean-up and disposal issues associated Moreover, the process has limitations as it is not suitable with traditional lead-based ammunition. for high melting point materials. Another weakness in The Ecomass Compounds are produced under an exclu- this processing system is the high capital costs required sive license by Technical Polymers in Buford, Georgia with especially for the forging equipment. production rates varying from 45 to 1,350 kg/hr. “Technical Dr Afian’s states that using the MIM process counters Polymers has a long history of successful, innovative, the shortcomings of the conventional method of producing composite material formulation and production. We are very the metal plates. MIM has several proven benefits as well pleased to have this level of technical expertise associated as being cost effective. This research now is in pre- with Ecomass Compounds”, said Robert Durkee, President commercialisation stage with the collaboration between of Ecomass Technologies. SIRIM Berhad, the Medical Faculty of International Islamic www.ecomass.com University Malaysia and True Mission Sdn Bhd under the Technofund grant from the government of Malaysia. For more information contact Dr Mohd Afian Omar, Kinetics goes multilingual [email protected] with on-line MIM design guide

Kinetics Metal Injection Molding of Wilsonville, Oregon, USA, has revamped its website making the newly launched version available in simple Chinese, German and Spanish as well as English. Included is an on-line 33-page design guide which provides comprehensive information on design criteria for MIM parts. Criteria includes incorporating corner breaks and fillets, holes and slots, undercuts (external/internal), threads, ribs and webs, knurling, lettering and logos, gating, sink and knit lines. The design guide also covers maximum and minimum MIM fracture fixation plates produced by SIRIM Berhad, wall thickness achievable in MIM, dimensional tolerances, Malaysia secondary operations including surface finishing and plating, and heat treatment. Downloadable ‘Material and Property Data Sheets’ for assistance in determining the best material solution for your MIM application are also provided. Submitting News Kinetics has been producing MIM parts since 1982 and currently operates out of a 50,000 ft2 facility in Wilsonville, To submit news to Powder Injection Moulding International USA. please contact Nick Williams: www.kinetics.com [email protected]

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September 2010 front section new12 12 9/10/2010 12:27:42 PM September 2010 front section new13 13 9/10/2010 12:27:44 PM Industry News

ATW announces the opening of Feedstock provider Parmatech-Proform’s Rhode Island MIM Polymer-Chemie facility re-established as

ATW Companies, a provider of custom According to Peter C. Frost, PolyMIM GmbH manufactured metal components and president of ATW Companies, “We are services headquartered in Warwick, very excited to be opening Proform’s The Metal Powder Compound Division Rhode Island, USA, has announced new East Providence facility, where of Polymer-Chemie GmbH, founded the grand opening of Parmatech- we will showcase our technical MIM in 2005, has become an independent Proform’s new manufacturing facility expertise. MIM has established itself legal entity as of August 2010 as the in East Providence, Rhode Island. The as a mainstream metal fabrication newly founded PolyMIM GmbH. Jochen company focuses on metal injection technique, and the existence of two Eichstädt and Dirk Breitbach were molding and secondary MIM operations separate facilities offers significantly appointed General Managers of the for the medical, telecommunications, enhanced logistical, security, and company. World PM 2010 - Florence firearms, hand tools, semiconductor, redundancy benefits. It also places us PolyMIM GmbH develops and and electronic packaging markets. The closer to customers and markets.” markets compounds for metal injection Visit us at Booth 54 new facility will serve as Proform’s Among ATW’s many product moulding. The separation from headquarters. capabilities are waveguide tubing, Polymer-Chemie creates a clear differ- The grand opening event will take machined parts, sidewall frames, entiation from PVC Compounds, the place at the facility on 21 October medical components, precision metal primary business of Polymer-Chemie. 2010 and will feature remarks by tubing, and stamped metal parts. ATW As with former spin-offs Techno- ATW executives, a tour of the factory Companies is the parent company of A. Compound GmbH, Polyblend GmbH and visits from community leaders. T. Wall Company (Warwick, RI), Judson and the joint venture with Mitsui Proform is a wholly owned subsidiary A. Smith Company (Boyertown, PA), Chemicals called Sun Alloys Europe of ATW Companies, acquired by ATW Parmatech Corporation (Petaluma, GmbH, PolyMIM GmbH is a subsidiary in 2009 specifically to augment and CA), and now Proform (East Provi- of the Polymer-Chemie group of complement Parmatech’s California- dence, RI). companies. based MIM operation. www.polymim.com MIM producer PCC-AFT PHOENIX takes a unique approach to SCIENTIFIC educating end-users We increase Parts producer PCC Advanced Forming Technology, head quartered in Longmount, CO, USA, and with additional INDUSTRIES production facilities in Hungary, is taking a hands-on approach to educating users as to the benefits of the MIM Concept design to process. engineering reality Productivity! The company runs a series of free introductory seminars, called “The AFT-MIM School”, in both USA and Europe Europe’s specialist engineers specifically targeted at the end-user community, including for design and manufacture of engineers, buyers and quality control specialists in the With our PM Tooling System for flexible and quick resetting! innovative materials processing mechanical components field. The result is a series of two day courses that provide Atomisers a comprehensive introduction to all aspects of MIM Hot/Cold Gas processing. Sessions are dedicated to: You can find out more about the EROWA quick change tooling Water • Powders and Compounding Vacuum Gas Recycling • Injection Moulding system for dies and die-plates on www.erowa.com Apex Business Park, Powder Classifiers Hailsham BN27 3JU, UK • Designing for MIM Trial Powder Service Tel: +44 (0)1323 449001 • Manufacturing Steps Melt Spinners Fax: +44 (0)1323 449002 [email protected] • Quality Wire Casters www.psiltd.co.uk • Secondary Operations Participants also learn how to combine two materials in one component, design with internal threads that require no machining, and combine several components and

Visit us at booth 75 assemblies into one part. For further information and registration details contact Mitch Lehigh, [email protected]

System solutions from  Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International  www.erowa.com one single source [email protected]

September 2010 front section new14 14 9/10/2010 12:27:49 PM September 2010 front section new15 15 9/10/2010 12:27:49 PM Industry News

homogeneous melt with minimal flow Battenfeld launches new ‘MicroPower’ lengths. The injection aggregate allows injection moulding machines processing of all materials suitable for injection moulding up to a volume of 3 Wittmann Battenfeld, headquartered In order to offer customers a cm³ and feeding of all commonly used in Kottingbrunn, Austria, has been significant additional benefit, the standard granulate sizes. a leader in micro injection moulding machine concept has been laid out to Apart from the unique high quality machines since the introduction of its accommodate possible downstream of moulded components, the main Microsystem 50 in 1998. The company manufacturing steps by easy connec- benefit of MicroPower is its cost-effi- has now completely redeveloped a tion of additional modules with various ciency. Thanks to shorter cycle times new micro injection moulding machine functions. This includes, for example, as well as lower material and energy within the MicroPower brand. fully automatic quality monitoring or consumption, cost savings of about 30 The company claims that Micro- packaging of parts, either individually to 50 % can be realised compared to Power machines outperform their or in bulk. Even complex parts, such as conventional machines. Visit us at stand 59 predecessors as well as competing insert-moulded or multi-component systems by offering a high degree of parts, can thus be manufactured cost-efficiency, precision, flexibility and without any problems and at low cost, energy-efficiency. The two all-electric state Battenfeld. models of the series with 5t and In the area of automation, a special 15t clamping force lend themselves robot for handling small parts has been to a considerably extended field of developed. The Vertikal-SCARA W8VS2 application. On each of the machines, robot, driven by three servo motors, a latest-generation injection unit with a is able to remove and further process shot volume of 1 or 3 cm³ can be used. micro parts with high dynamics and The company also indicates that accuracy. Here, special attention MicroPower’s processing ability is has been paid to complex tasks not restricted to micro parts, and that such as insert and insert-moulding thanks to the increase in clamping technologies. force and shot volume, the machine can The UNILOG B6 control system, Fig. 1 Front view of the MicroPower 15 produce “larger” parts or accommodate facilitating the operation of injection injection moulding machine moulds with a larger number of cavities. moulding machines together with The highly functional basic model all integrated peripheral equipment, of MicroPower serves as the basis for is now available for all fully electric a highly accurate, extremely fast all- machine series, from the smallest electric injection moulding machine. to the largest model. Operation and The moulded parts can either just control of the injection moulding drop down through the ejection chute machine and all integrated peripheral or be removed by a handling device. equipment can be learned very quickly The generous free space around the and intuitively. clamping unit offers enough room even The injection unit of the MicroPower Fig. 2 Cross-section of the MicroPower for bulky tooling. is capable of injecting thermally injection unit

Feedstock for Metal Injection Molding

At Advanced Metalworking Practices feedstock production is our only business. Our products are used widely for applications in industries such as medical and orthodontic, electronics, hardware and sporting goods.

ISO 9001:2008 certified Contacts: ® William R. Mossner Supplier of quality feedstock ADVAMET Dwight Webster Feedstock production from 25 lb to 1700 lb in one batch Advanced Metalworking Can supply customers with lower cost, off-the-shelf, Practices, LLC 401 Industrial Drive standard 4605 Alloy Steel and 17-4 PH Stainless Carmel, IN 46032, USA Supplier of Customized feedstock made from numerous e-mail: [email protected] ferrous and non-ferrous metals and alloys. Phone: +1 317 843 1499 Fax: +1 317 843 9359 High Quality Feedstocks since 1988 - longer than any other supplier www.advancedmetalworking.com

 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

SeptemberGeneralGeneral cremercremer 2010 ad.indd ad.inddfront section 11 new16 16 9/10/20109/1/20109/1/2010 12:27:51 4:50:144:50:14 PMPM September 2010 front section new17 17 9/10/2010 12:27:57 PM Industry News Industry News

Fall in Japan’s MIM sales steeper than Defective parts Indian MIM producer expands expected database opened US sales base Total annual sales of MIM components of the global economy. The breakdown to PM community Indo-US MIM Tec Pvt. Ltd, one of the world’s largest producers in Japan in 2009 fell to 10.9 billion of end-user markets has also been of MIM products, reports Yen (US$78 million) in 2009, the revised by the JPMA with automotive The lack of an adequate inspection that as a result of impressive lowest level since the Japan Powder MIM parts recording a lower 17.5% system in PM part manufacturing has recent sales growth in North Metallurgy Association (JPMA) began market share compared with nearly important implications from the point America the company has collecting sales statistics for the 23 20% in 2007. Medical appliance parts of view of quality assurance, since it had to expand its sales base MIM producers in Japan in 2004. increased their share to 16.8%. increases the design costs and the in Princeton, New Jersey. The fall represents a 21.2% decline The JPMA is forecasting MIM sales time of a tool set for a new product. Indo-MIM operates from a from the previous year and was steeper to recover to 11.779 billion Yen in 2010 The MFKK Invention and Research 25,000m2 plant in Bangalore, than originally estimated by the JPMA and 12.41 billion in 2011. This is still Centre Services based in Budapest, India where it focuses on MIM (see PIM International, March 2010), some off the high of 15.7 billion Yen Hungary, is coordinating a project called part production, but recently and was due to the rapid deterioration MIM sales achieved in 2007. SINTEST to develop a highly effective added investment casting and Indo-MIM’s MIM manufacturing and cost-efficient in-situ system that machining facilities. and finishing facility, Bangalore, Sales of MIM Products in Japan can detect deficiencies in sintered www.indo-mim.com India FY2004-09 are results, 2010-11 estimated (Million Yen) parts based on ultrasonic technology. 18000 MFKK is additionally building up a

16000 database allowing PM part producers to contribute their own data on defects MPIF launches ‘PM sustain- 14000 found in PM parts which will be incorpo- 12000 rated into an on-line database. ability initiative’ 10000 Dr Andras Bulkai, project coordinator, The MPIF has released a new report called: ‘Powder Metallurgy 8000 stated that companies which contributed – Intrinsically Sustainable’ which is aimed at recognising PM to the database would also have free 6000 as a ‘green’ technology. The report underlines the fact that PM, access to it, and in this way it is intended 4000 and this will also include MIM, has one of the highest material to produce a large and unique database 2000 utilisation rates (>95%) in the manufacture of metal components. that could be used to improve the quality Additionally, the PM process uses less energy than other 0 of PM parts. The project is scheduled to processes such as cold and warm extrusion, hot forging and 2004 2005 2006 2007 2008 2009 2010 2011 be completed by the end of 2010. machining. www.mfkk.hu Data courtesy JPMA PM is also said to present fewer environmental hazards than competing processes, states the MPIF report. Final machining operations on PM parts for special tolerances are minimal, and results in a reduction of cutting fluids per pound produced. www.mpif.org

90o cable connector using MIM

IMS Connector Systems GmbH of Löffingen, Germany, is using metal injection moulding (MIM) to produce connector housings such as the 90° MCX cable connector. The company states that conventional RF connector housings require a number of machined components which are pressed and screwed together. Its MIM housings are produced as one piece and IMS claims a number of advantages for MIM over the machined metal components previously used. These include outstanding vibration resistance through high retention forces compared with standard connectors, improved corrosion resistance, robustness and abrasion resistance. The MCX connector, for example, is a one- piece robust housing and its significantly improved vibration security makes the connector reliable even for the most demanding environments. The 90° MCX cable connector produced by www.imscs.com IMS Connector Systems GmbH

 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September 2010 front section new18 18 9/10/2010 12:27:59 PM September 2010 front section new19 19 9/10/2010 12:28:03 PM Industry News Industry News

Lömi secures a major Indian Downsizing of medical devices favours Egide announces order for large volume metal injection moulding success in MIM

debinding tanks Outlining the ABCs of metal injection “Whilst demand for mainstream medical market moulding in a recent review published medical components remains Lömi, the market leader in explosion-proof solvent in the on-line ‘Medical Design’ generally steady, the orthodontic Egide, based in Suffolk, UK, recently debinding systems for PIM, based in Aschaffenburg, magazine, Ted A Tomlin, technology and elective surgeries sectors have celebrated the securing of a five year Germany, has stated that it has strengthened its market advisor to metal injection moulding been adversely affected”, said Tomlin. agreement worth an estimated £1.2 position with another major order from an Indian-based producer FloMet LLC of DeLand, The hearing aid market has recently million to supply MIM components to a MIM producer. The order for the high-volume debinding Florida, USA, stated that some of the become a focus for metal injection major UK medical company. and solvent recovery facilities will be delivered in the most common medical components moulding producers with metal injec- Chris Conway, Managing Director, st nd 1 and 2 quarter of 2011. Visit Lömi at the PM World produced by metal injection moulding tion moulding RF-shielded hearing told PIM International, “This agreement Congress, stand 81. include laparoscopic parts such as aid cans produced to net-shape and is just another forward step in the long- www.loemi.com biopsy cups, dissectors, and instru- a wall thickness measuring 0.28 mm standing relationship between Egide ment handles as well as hearing-aid thick replacing cans produced from and its partners. It demonstrates our cans and orthodontic brackets. 80% nickel alloy sheet metal. Metal quality, know how, expertise and reac- Tomlin stated that the main attrac- injection moulding is said to cut costs tivity not only in the medical market but tion of metal injection moulding is by 30 to 40%. the continuous supply of components its ability to produce small, complex Tomlin concluded by stating that in to various other industry sectors”. parts more quickly and at lower cost metal injection moulding is driven According to Philippe Brégi, than competing technologies such as by the same market forces as other Chairman and CEO of Egide, “Quality machining and investment casting. manufacturing processes, and is and technical know-how of Egide UK In recent years many of the medical subject to the call for ‘Better! Cheaper! allow our subsidiary to be recognised devices have seen significant down- Faster!’. The metal injection moulding as a leader for MIM components sizing. Tomlin said that whereas the industry must respond with new and used in the medical, automotive, early metal injection moulded parts for innovative materials and overcome gas analysis, industrial, telecom and Visit us at booth 35 minimal invasive surgery measured a whole new set of manufacturing aerospace markets. We are very proud about 11 to 12 mm, today they are half ‘impossibilities’. about this significant contract.” that size at 5 to 6 mm. “Laparoscopic www.flomet.com www.egideuk.com Lömi solvent debinding tanks used for MIM parts are getting even smaller” he said. 2010 EPMA Summer School review

The 10th EPMA PM Summer School, and the second to be part funded by the EPMA itself, took place at the University CM Furnaces, long recognized as an industrial leader in performance-proven, high Carlos III of Madrid, Spain, from 5th to 9th July 2010. temperature fully continuous sintering furnaces for MIM, CIM and traditional press Continuing the trend of previous summer school successes, and sinter now OFFERS YOU A CHOICE, for maximum productivity and there was a 3 to 1 ratio of applications versus places. Professor José Torralba and his excellent team at the elimination of costly down time. University Carlos III coordinated and hosted the event with administrative support from Joan Hallward of the EPMA. Choose one of our exclusive BATCH hydrogen atmosphere Rapid Temp furnaces. More than 50 students from 16 countries throughout Europe Designed for both debinding and sintering, these new furnaces assure economical, not only had the opportunity of listening to leading PM simple and efficient operation. experts from both academia and industry, but were also able to discuss and solve problems together during their stay. OR... choose our continuous high temperature sintering furnaces with complete Laboratory practice was carried out at the University automation and low hydrogen consumption. Carlos III where participants had hands-on experience of powder analysis, cold isostatic pressing and MIM. All CONTACT US for more information on our full line of furnaces with your students additionally received a complimentary copy of choice of size, automation, atmosphere capabilities and Powder Injection Moulding International. temperature ranges up to 3100˚F / 1700˚C. No Summer School would be complete without the now traditional EPMA “Eurovision Song Contest”, which regaled diners until midnight on the last night at the restaurant in the park “La Chopera”. The EPMA plans to run another PM Summer School next E-Mail: year. Further information will be made available on the EPMA website early in 2011. For any additional information [email protected] FURNACES INC. contact Joan Hallward at the EPMA. Web Site: 103 Dewey Street Bloomfield, NJ 07003-4237 http://www.cmfurnaces.com Tel: 973-338-6500 Fax: 973-338-1625

0 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September 2010 front section new20 20 9/10/2010 12:28:06 PM September 2010 front section new21 21 9/10/2010 12:28:06 PM Industry News Industry News

PM World Congress: Industry producers Advanced Powder Products and suppliers head to Florence expands MIM production

The World PM2010 Congress & Full abstracts from papers facilities Exhibition, taking place in Florence, included in all of the above sessions Advanced Powder Products, Inc. (APP) has broken ground Italy, 10-14 October, will be the most are available to view on-line at www. to a World PM Exhibition” commented on a 5,100 sq. ft. expansion to its headquarters and manu- important event of the year for the pim-international.com/events. Andrew Almond, World PM Exhibition facturing facility in Philipsburg, PA, USA. The expansion will international PM and PIM industries. A special interest seminar will also Manager at EPMA. “Selling out the approximately double APP’s manufacturing space and will Around 600 technical presentations present “A Global View on Metal Injec- exhibition space helps place the entire also include an enlarged and upgraded QC lab, and additional are included in both oral and poster tion Moulding” through case studies event on a very positive footing, as the engineering offices, conference rooms and employee support format, along with a number of special from Asia, Europe and North America. event looks to be the start of a return areas. The expansion is expected to be completed in the 4th interest seminars. to growth for the PM sector. We look EuroMIM meeting quarter of 2010 and will support APP’s plans to increase its Powder injection moulding features forward to a successful and produc- The EPMA’s European Metal Injection manufacturing staff during fiscal 2011. prominently, with the following tive exhibition for both exhibitors and Moulding Group (EuroMIM) will be Don Kupp, Business Development Engineer at APP sessions devoted to the processing of delegates alike.” meeting in Florence immediately prior told PIM International, “The added space will immediately PIM parts: The World PM2010 Exhibition to the World Congress, on Sunday 10 enhance our manufacturing work flow and productivity, will open from 11am on Monday • Session 16: PIM Titanium October, 15.00 - 16.30. This is an open while providing space for future equipment acquisitions. 11th October in the Central Pavilion, • Session 22: PIM – Materials meeting and anyone interested in The expanded manufacturing area will allow for the addition Fortezza da Basso Congress Centre, • Session 28: PIM- Superalloys and attending should contact the EPMA. of one continuous furnace for micro-part manufacturing Florence, Italy and will close at 2pm Composites and additional batch sintering furnaces. This space will International trade exhibition on Thursday 14 October. The World • Session 34: Miniaturization & also allow room for additional injection moulding machines The World PM2010 has now sold out, PM2010 Exhibition will run for 4-days in MicroPIM and secondary operations equipment. Additional injection with over 120 stands being taken up total and includes exhibits from across moulding machines, debinding/sintering furnaces and related • Session 40: Powder Injection by PM related companies. The last the PM supply chain and from across manufacturing equipment are currently being evaluated with Moulding of Composite Parts few remaining stands were only sold the globe. purchase and installation planned for early 2011”. For more • Session 46: PIM – Feedstock in early September, state the EPMA, Further information and up-to-date information contact Don Kupp, email: [email protected]. Materials shows confidence starting to trickle timing schedules can be found at: www.4-app.com. • Session 52: PIM - Ceramics back into the industry. www.epma.com/pm2010 • Session 58: PIM – Modelling & “Being able to announce the exhibi- Simulation tion area has sold out is a great start

Yuelong Superfine Metal Co., Ltd Powders for MIM

An architect’s preview of APP’s new MIM facilities

Carbonyl iron powder New name for Reimelt Gas atomized powder Henschel GmbH Following the recent affiliation of Reimelt Henschel GmbH to the Zeppelin Group based in Friedrichhafen, Germany, the company will now operate under the name of Zeppelin Water atomized powder Reimelt. The company’s Henschel Mixing Technology division based in Kassel, Germany, develops and manufactures process technology systems for the handling of powders, viscous and Visit us at booth 92 liquid raw materials, as well as powder/liquid mixers for a wide range of industry sectors including the production of Yuelong Superfine Metal Co.,Ltd ‘ready-to-use’ PIM feedstock. The PIM feedstock is said to Global Business Unit have a narrow particle size distribution and can be batch 3/F,Complex Building, Hi-Tech Zone, Port Road European Office produced in less than 20 minutes. FoshanHeadquarters 528000, Guangdong, China www.reimelt-henschel.com Tel: +86 757 8393 8576 Fax: +86 757 8393 8579 Email: [email protected] www.yuelongpowder.com

 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September 2010 front section new22 22 9/10/2010 12:28:10 PM September 2010 front section new23 23 9/10/2010 12:28:13 PM Industry News Industry News

MTU Explores potential for MIM jet engine components

MTU Aero Engines GmbH of Munich is Germany’s leading aero engine manu- facturer and an established global player in the aerospace industry, with reported sales of around €2.6 billion in 2009. As part of MTU’s drive to improve Fig. 2 Volume comparison of the MIM superalloy vane in the the efficiency and performance of green and sintered state (Courtesy MTU AeroEngines GmbH) Fig. 1 The size of the high pressure compressor parts in an aero engine is suited to advanced aero engines, the company the MIM production process. One compressor stage typically includes 80 to 150 vanes has in recent years been looking at size distribution and which can range in weight from 5 to 150g. (Courtesy MTU AeroEngines gmbH) metal injection moulding (MIM) as a optimum powder filling more cost-effective manufacturing Müller, MIM stator vanes made from are said to have HCF properties close in the MIM feedstock. method for complex shape compressor gas atomised nickel base superalloy to those of the forged material. Any imperfections in vanes located in the high pressure powders capable of operating at MTU has not revealed the specific the powder such as compressor of aero engines which temperatures of up to 650°C, have been composition of the argon atomized ceramic inclusions operate at elevated temperatures. One engine tested with a view to replacing nickel-based superalloy used to from the atomisation such engine is the Joint Technology vanes made from forgings or castings. produce the MIM vanes, stating only process are reduced Demonstrator Programme engine Forged vanes require time consuming that it is a proprietary alloy material. to a defined limit by (JTDP03) which has been developed and costly milling or electro-chemical Nearly 100% material usage gives sieving. jointly with Pratt & Whitney (P&W) in machining (ECM) whereas cast vanes MIM a significant cost advantage Fig. 3 Four MIM superalloy vanes The report states the USA. had lower high cycle fatigue (HCF) despite the high cost of the nickel-base brazed together to form a vane that the injection According to an unclassified report strength and did not guarantee accept- superalloy powder used as a starting cluster (Courtesy MTU AeroEngines moulding process written by MTU researchers Siegfried able quality for the thin leading and material, states the report. The powder GmbH) can produce special Sikorski, Max Kraus and Dr Claus trailing edges. MIM superalloy vanes is sieved to obtain the desired particle imperfections such as porosity due to the thin sections of the part hampering the flow of the feedstock. The very thin sections of the leading and trailing edges of the vanes are critical in this respect. Also the parting lines of the mould and the ejectors can mark the parts in unfavourable areas. The injection moulding parameters and the gating system have been optimised to Anlagenbau GmbH achieve homogeneous density of the green parts. MTU also reports that it has optimised debinding and sintering conditions to achieve high sintered density plus the required microstructure, e.g. grain size, in the complex 3D MIM vanes. Special setters are used to prevent shape deviations and distortions and the heating and cooling rates A NEW APPROACH are adjusted to restrain distortions and shrinkage stress. The optimised sintering conditions and thermal treatment parameters resulted in MIM vanes with high dimensional in quality and low surface roughness. The grain size in the MIM superalloy vanes gave them a measurable advantage over similar alloys in the cast condition, and similar strength and ductility values to forged materials, including fatigue GAS PRESSURE SINTERING strength determined on MIM specimens by high-cycle fatigue at relevant operating temperatures. Any residual porosity in combined processing: the MIM vanes is eliminated by hot isostatic pressing. The single MIM vanes are subsequently brazed to form a vane cluster of four vanes. After successive brazing of thermal debinding and gas pressure sintering a conventional honeycomb seal onto the inner shroud, th vane cluster prototypes were qualified for full-scale engine testing. The report states that the honeycomb seals are another potential application for MIM as they exhibit a complex shape and similar high production volumes to the FCT Anlagenbau GmbH stator vanes. Other potential high volume applications for Hönbacher Str. 10 Tel. +49 3675 / 7484-0 email: [email protected] MIM in jet engines made by MTU include adjusting levers, D-96515 Sonneberg Fax +49 3675 / 7484-44 web: www.fct-anlagenbau.de locking nuts or retaining plates. These have complex shapes and include tiny features suitable for the MIM process.

 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 

September 2010 front section new24 24 9/10/2010 12:28:14 PM September 2010 front section new25 25 9/10/2010 12:28:17 PM Industry News Industry News

Research efforts Physical and Mechanical ProPerties of Laboratory/ sintered titaniuM alloy Production Z Blade highlight trends .CO.UK Sintered titanium Mixers Properties MPIF 35 in PIM titanium alloy 7 implants Density (g cm-3) 4.39 >96% New MZ Hardness (Hv) 381.20 300-400 Titanium and its alloys are extensively Sigma Mixer used for orthopaedic and dental Porosity (%) 2.47 <5 implants and they have been the Shrinkage (%) 11.86 12-15 target of the MIM industry and supporting academic research for a Strength (MPa) 541.53 >700 number of years. Porous titanium, Elongation (%) 0.90 10-15 whilst offering lower mechanical properties compared with the solid material, does help to compensate Table 1 Physical and mechanical properties of sintered for the mismatch in stiffness between titanium alloy. (from the paper ‘Injection Molding of Tita- Mixing for Metal Injection Moulding? the implant and bone tissue thereby nium Alloy Implant for Biomedical Application using Novel reducing ‘stress shielding’ and Binder System based on Palm Oil Derivatives’ by R. Ibrahim, • Winkworth Laboratory/Production Z (Sigma) blade promoting long-term fixation. Thus a etal (Advanced Materials Research Centre, SIRIM Berhad, mixers - proven in Metal Injection Moulding porous titanium implant material with Malaysia) published in American Journal of Applied Sciences, • Used by Researchers and in Production - worldwide Fig. 1 SEM photographs of porous MIM tita- adequate open cellular pore structure 7, (6), 2010, 811-814 nium: (a) Sample 1; (b) Sample 2; (c) Sample • Complete process control and monitoring to allow for bone ingrowth in combina- 3; (d) Sample 4; (e) Micropore (from paper: • Easy Clean – just 5 minutes – batch to batch tion with appropriate mechanical macro pores in (c) are partly interconnected and in (d) ‘Porous titanium implants fabricated by • Designed and Made in England properties is considered to be the interconnected. The sample in Fig.1 (e) showed a much Metal Injection Molding’, by Chen Liang-jian ideal bone substitute. finer type of pore with a size of several microns. It was etal (State Key Laboratory of Powder Metal- There are a number of ways to concluded that the cell walls of the porous Ti are rough For more information about Winkworth Sigma Z Mixers lurgy, Central South University Changsa, produce porous titanium, including and honeycomb-like and that the interconnected porosity Call Sales on: +44 (0)118 988 3551 China), published in Trans. Nonferrous Met. is appropriate for the in-growth of bone tissues and the partial sintering of spherical powders E: [email protected] Soc. China, 19 (2009), 1174-1179) transport of body fluids. In another study reported in the American Journal of W: www.mixer.co.uk Applied Sciences (Vol.7, No.6, 2010, 811-814) researchers or wires or sintering of powders around a temporary at the Advanced Materials Research Centre, SIRIM space-holding phase, but metal injection moulding Berhard, Malaysia, have published results into the use of (MIM) in combination with the space holder method a novel binder system based on palm stearin for powder appears to have the edge when it comes to mass injection moulding of titanium alloy components having production of complex 3D shapes. potential use in biomedical applications. The palm oil According to a paper published in Trans. Nonferrous derivative, palm stearin, has been formulated and evalu- Met. Soc. China (Vol.19, 2009, 1174-1179) the State ated as a possible additive to the polyethylene binder Key Laboratory of Powder Metallurgy at Central South system because of its advantages during the various stages University in Changsa, Hunan, China, has successfully of the debinding process and the resulting high sintered adopted MIM technology to produce porous Ti implants density. using the space holder method. The researchers at AMRC used a combination of 40% polyethylene and 60% Changsa used HDH titanium powder with <77 micron palm stearin as the binder which was mixed with spherical particle size and sodium chloride (NaCl) as the space titanium alloy powder having a 25 micron particle size holder material. The NaCl had a <290 micron particle using a Z-blade mixer at 130-160°C for 2 hrs. Optimum size and five different volume fractions of NaCl were powder loading in the feedstock was found to be 65-67 used (30 to 70%) in order to study their effect on vol.% for good mouldings. Shear rate and viscosity of the porosity and pore shape. Both Ti and NaCl powders feedstock should be in the range of 100-10000 sec-1 and have irregular shapes. The injection moulding binder 1000 Pa.s, respectively and the recommended temperature was based on a multi-component system comprising range for injection moulding for the Ti alloy feedstock is polyethylene, paraffin wax, polyethylene glycol, and reported to be 110-140°C. stearic acid. The green mouldings were subjected first to a solvent After moulding, the organic part of the compact extraction step where two thirds of the binder system was removed by solvent and thermal debinding, and was removed. The parts were then immersed in heptane the NaCl space holder was removed by dissolution in for 6 hr at 60°C and heated up to 1150°C for sintering a water bath before the final thermal debinding step in under vacuum for 5 hr. The results (Table 1) show that argon at 720°C. the sintered titanium alloy parts produced using the palm Two types of pores were found in the resulting stearin as a binder component achieved the minimum sintered samples which had porosity of up to 71.6%. property requirements as per MPIF Standard 35 for the Ti The samples shown in Fig. 1 (a) and (b) contained alloy with the exception of tensile strength and elongation. interpenetrating macro-pores in the 50-300 micron The latter were negatively impacted by the formation of a range formed by space holder removal, whilst TiC phase in the sintered Ti alloy parts.

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September 2010 front section new26 26 9/10/2010 12:41:51 PM September 2010 front section new27 27 9/10/2010 12:41:52 PM Industry News Industry News

MPIF award winning MIM parts 2010 Winners of the 2010 PM Design Excellence Awards Competi- tion, sponsored by the Metal Powder Industries Federation, were announced at PowderMet2010. As in previous years, the MIM sector scooped some of the key awards.

Grand Prize Winners Stainless steel hunting arrow tip: Smith Metal Products, Fig. 3 MIM industrial lock components manufactured by Advanced Lindstrom, MN, USA, received the Grand Prize in the Hand Materials Technologies Pte Ltd Tools/Recreation Category for a 17-4 PH stainless steel hunting arrow tip (Fig. 1), called a shuttle T-lock broadhead, made by MIM for Trophy Taker, Inc., Plains, MT, USA. Formed to a final density of 7.6g cm3, the unusual shape extends the design engineering advances of the MIM process. Other processes were considered but could not provide the necessary geometry for commercial production, and the prototypes cost many times more than MIM. The broadhead has a yield strength of 137,000 psi and a tensile strength of 159,000 psi. The ferrule hardness is 36 HRC and the blade hardness is 38 HRC. Secondary operations are limited to Fig. 4 MIM upswept safety grip manufactured by Megamet Solid final grinding of a razor sharp edge on the tip of the ferrule Metals, Inc and the leading edge of the blade. Military “safe and arm” rotor: FloMet LLC, DeLand, FL, into a housing to provide the two-stage safety for the explosive USA, won the Grand Prize in the Aerospace/Military Category device. It replaced a zinc die casting whose mechanical proper- for a safe and arm rotor (Fig. 2) used in an explosive device ties were ultimately not consistent enough to pass validation for a US Department of Defense application. Produced by testing. MIM, the 316L stainless steel part is formed to a density Industrial lock parts: Advanced Materials Technologies of 7.6g/cm3. Its significant properties include an ultimate Pte Ltd, Singapore, won the Grand Prize in the Industrial tensile strength of 75,000 psi, yield strength of 25,000 psi, Motors/Controls & Hydraulics Category for four complex 50% elongation, 140 foot-pound impact strength and 67 HRB 316L stainless steel MIM parts: lock cover, lock barrel pin, hardness. The complex shape features numerous outside lock barrel boss and lock barrel square (Fig. 3). These are radii and angular surfaces. At least 12 functional features assembled into a locking device for heavy machinery operating and surfaces are geometrically controlled by concentricity, in harsh environments. Choosing the MIM process over casting profile, and true position tolerances. The part is assembled provided superior surface finish that did not require polishing, enhanced corrosion resistance, as well as a 30% cost saving. The parts are formed to a density of 7.5g/cm3 and feature a tensile strength of 75,000 psi, a yield strength of 25,000 psi, 50% elongation, and a 67 HRB hardness. They must undergo cyclical rotational testing of more than 300,000 cycles and a 48-hour salt-spray test.

Award of Distinction Pistol upswept grip safety part: Megamet Solid Metals, Inc., Earth City, Mo., won an Award of Distinction for an upswept Fig. 1 A MIM Shuttle T-Lock Broadhead produced by Smith Metal grip safety part (Fig. 4) used in the 1911-style 45-caliber Products pistol made by Colt’s Manufacturing Company, LLC., West Hartford, Conn. The complex MIM 17-4 PH stainless steel part is produced to a density of 7.6g cm3. The upswept design of the grip safety part, which was traditionally investment cast, would previously require extensive secondary machining. Switching to the MIM process reduced customer lead times and provided exceptional cost savings, in addition to increasing production rates and producing a more uniform part. The upswept grip safety performs several functions: it blocks the trigger from firing, shields the hammer from impacting or injuring the shooter’s hand when the pistol cycles, and interacts with the shooter’s palm for comfort. Colt performed a 10,000-cycle test Fig. 2 A MIM “safe and arm” rotor manufactured by FloMet LLC to qualify the part.

28 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 29

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Untitled-1September 1 2010 front section new30 30 9/10/20109/10/2010 10:42:30 12:42:01 AM PM September 2010 front section new31 31 9/10/2010 12:42:02 PM MIM in Italy: an introduction MIM in Italy: an introduction

Fig. 1 A view of the injection moulding area at Leone Spa Fig. 2 Debinding and sintering facilities at Leone Spa

alternative to investment casting for orthodontic parts. In 1993 the MIM project at Leone was started, particularly thanks to the collaboration with Arburg who proposed injection moulding machines dedicated to MIM and made Fig. 4 Vacuum sintering furnaces produced by TAV at Mimest’s plant near Fig. 5 Selection of MIM parts produced by testing possible at their development plant in Lossburg, Trento Mimest for a novel corkscrew Germany. Our first MIM production cell was set up in 1995, following an agreement with BASF for feedstock supply.” market for MIM products into new niche areas such as MIM The need for technology promotion All MIM parts produced at Leone are for the company’s own medical implant products and MIM diamond beads for the range of orthodontic products and the company does not diamond tool sector. As the following company reports will demonstrate, Italy’s manufacture parts for other industries. Whilst Italy’s strong automotive industry has been happy MIM industry has no shortage of technical capability and “At Leone we now have four Arburg injection moulding to adopt press and sinter technology, there appears to be a expertise. Until, however, more of the country’s designers machines, three dedicated to MIM and one to CIM, with an general lack of enthusiasm when it comes to supporting the and engineers become aware of the process, the market for overall production capability of 3 million pieces per year. Fig. 3 Examples of MIM orthodontic products manufactured by domestic Italian MIM industry. MIM products will continue to fall short of reaching its full Leone Spa potential. We still use BASF’s Catamold feedstock system today. Equipment supply Competence We, of course, have other manufacturing processes in Versatility house, and besides MIM these are micro machining TAV SpA is Italy’s only supplier of production equipment Innovative (drilling, milling, turning, shearing), brazing, laser specifically tailored for MIM. Located in the northern Italian ...the world of welding and marking, surface polishing and assembly”, city of Caravaggio, the company has been manufacturing continued Dolfi. industrial vacuum furnaces since 1984. It was also in 1995 that the second company to establish To-date it has produced more than 400 furnaces that MIM Debind and Sinter Furnaces is the research subsidiary of a MIM production facility in Italy, Metrocast Italiana, started are installed and running in over 30 countries worldwide. for Metal and Ceramic Injection Molded Materials the University of Applied its MIM operations. Metrocast, a long established manu- The company’s MIM furnace range is currently used for Sciences Wiener Neustadt, t Metal or graphite hot facturer of investment cast products, looked to capitalise on the sintering of stainless steels, titanium, ceramics and Austria. As interface zones interest in this new process from its existing customer base hardmetals. (Powder) Injection Moulding between industry, science and education we are (see our full report on page 41). t Sizes from 0.3–12 cu ft. pioneer in the field of

t Pressures from 10-6 torr– R&D at Italian universities Product Development powder injection 750 torr The market for MIM parts in Italy moulding. The University of Trento, under the leadership of Prof. Albert t Operates in Vac, Ar, N2, There is a feeling amongst the part producers visited by PIM Molinari, Professor of Metallurgy and Head of the Depart- Test Engineering and H2 International for this review that awareness of MIM tech- ment of Materials Engineering and Industrial Technologies, t All binders and feedstocks nology at potential end-user companies is very low. For this appears to be the most active centre for MIM related Measurement reason, the market for MIM components remains extremely research and development activity in Italy. Over 6000 units built since 1954 fragmented. There are of course a number of success The department’s work includes collaborative projects Rapid Prototyping t Over 80 different styles of batch and continuous furnaces stories, as highlighted in the following three company with parts producer Mimest on the development of MIM reports, and there is confidence that these successes can be implantable prosthesis parts. Papers published in PIM Inter- from 1 cu cm to 28 cu m. Custom sizes available. Project Management built upon in the future. national as a result of this collaboration include “Influence t Testing available in our Applied Technology Center of carbon content on microstructure and tensile properties furnaces to 2800°C The unusual nature of Italy’s economy is an additional factor that has had an effect on the growth of MIM. Domi- of the 17-4 PH stainless steel produced by MIM” (Vol. 2 No. 4 Innovative Software Systems t Worldwide Field Service and Spare Parts available nated by smaller family owned SME’s rather than blue chip December 2008, pp. 56-59) and “Mechanical properties and for all furnace makes and models. corporations, persuading these smaller companies to invest corrosion resistance of vacuum sintered MIM 316L stainless FOTEC Forschungs- und in the expensive tooling, as well as committing to sufficient steel containing delta ferrite” (Vol. 4 No. 2 June 2009, pp. Technologietransfer GmbH Centorr Vacuum Industries, Inc. production volumes, is a major challenge. 66-70). 55 Northeastern Blvd., Nashua NH t Toll free: 800-962-8631 Markets that the Italian MIM industry currently serves It is also understood that the Politecnico di Torino’s Viktor Kaplan- Strasse 2 Ph: 603-595-7233 t Fax: 603-595-9220 t E-mail: [email protected] Department of Materials Science and Chemical Engineering, 2700 Wiener Neustadt, Austria include firearms, textile machinery, food processing Tel. +43/2622/90333-0 under the leadership of Prof. Mario Rosso, has undertaken Details at equipment, eye wear parts and components for general Fax +43/2622/90333-99 www.centorr.com/pi engineering applications. Some producers, such as Mimest MIM related research work and the department has a well E-mail: [email protected] www.fotec.at (page 35) and MIMITALIA (page 38) are looking to expand the equipped laboratory for MIM technology.

32 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 33

September 2010 front section new32 32 9/10/2010 12:42:06 PM September 2010 front section new33 33 9/10/2010 12:42:11 PM MIM in Italy: Mimest spa Because you can never have Mimest: Developing a market too much industry knowledge in Italy for MIM titanium and performance products

th Mimest SpA is a small but ambitious metal injection moulding company The New 14 Edition 2010-2011 located in the outskirts of the Italian city of Trento, only a stone’s throw from the high peaks of the Italian Alps. As Nick Williams reports, this small start-up International Powder Metallurgy Directory company has developed a number of advanced and innovative MIM parts that demonstrate well its technical capabilities, from large titanium products to high performance motorsport components. 290 pages of new customers or suppliers The historic northern Italian city of of components by rapid prototyping. serving third parties. The laboratory • Listings of more than 4800 organisations involved in PM, Trento is not an obvious place to NCS’s facilities include a state-of-the- is extensively equipped with metal- from part producers to materials & equipment suppliers establish a new MIM company. Thanks, art testing facility, NCS Laboratories. lographic analysis equipment and serv- however, to a combination of regional This ISO 9001:2008 compliant facility is ices offered include SEM microscopy, • Products & services described using 200 product codes government support for technology also used to support the development EDS microanalysis and FEM analysis. A • Covers PM, MIM, Hardmetals, Sintered Magnets & much more... start-ups and the local materials of products by Mimest, as well as third company in the group is Tecres, a technology and engineering expertise at Trento’s internationally renowned university, Mimest SpA has succeeded in creating a niche for itself within 170 pages of market and technology Italy’s MIM community. The company was established in information 2005 by four engineers to “realise the potential of MIM in Italy”. The compa- • 170 pages of market and technology data ny’s initial ambition was to develop • Includes the 2010-2011 edition “Powder Metallurgy: A Global MIM components for the biomedical Market Review implant sector and although this remains a key area for ongoing • Written by invited experts from around the world development, is has since diversified into markets that have a broader commercial potential. In June 2009 the company changed its name from NCS Protech to Mimest, and now has a staff of six. Fig. 1 Metal injection moulded knee prosthesis components manufactured by Mimest Plus FREE on-line directory access Matteo Perina, Mimest’s Execu- from CrCoMo Alloy (ASTM F75) tive Officer, toldPIM International, • All purchasers can search our complete industry “We believe that we have a different database on-line for 12 months approach to some of the other MIM • Easily search for specific products by country or world companies in Italy. Everything that we region do has a scientific approach, influ- enced by our background as engineers. • Your essential reference guide to PM As such we are able to take on projects that require more in-depth knowledge than simply the ‘basics’ of processing straightforward MIM parts.” Mimest is part of a group of compa- Fig. 2 Microstructure of the knee prosthesis Fig. 3 Tensile data of various aged nies that includes New Cast Services (courtesy Trento University and Palloma examples (courtesy Trento University and All for only £190 inc. shipping www.ipmd.net Srl (NCS) based in Modena, a producer Mutterle) Palloma Mutterle)

34 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 35

SeptemberIPMD MARCH 2010 2010.indd front section 1 new34 34 9/10/20103/5/2010 12:42:12 9:19:50 PMAM September 2010 front section new35 35 9/10/2010 12:42:15 PM MIM in Italy: Mimest spa MIM in Italy: Mimest spa

titanium and stainless steel, with the customer using a limited edition run of the titanium version for a special “90th Anniversary” edition of it’s Gitzo branded Titanium Traveller tripod. The part was machined after sintering to remove supports and create an external thread. Other examples of MIM titanium parts commercially produced by Mimest are a titanium trigger for an Italian gun manufacturer (Fig. 7) and a small lightweight gear for high performance racing bicycles (Fig 8). The company typically uses Ti6Al4V feedstock manufactured by PolyMIM Fig. 4 MIM 316L motorsport exhaust components, including a green part (left), an as Fig. 5 A view of the interior of the exhaust GmbH (formerly Polymer Chemie). sintered part (centre) and a finished part (right) after various post-sintering operations component Fig. 9 A view of one of the two Arburg Allrounder injection moulding machines

metal finishing provider whose services ties of various aged examples. The Championship winning bike. Production & materials development of the MIM industry, include electroplating, oxidation, laser company worked closely with Trento “The challenge was to retain as with, for example, the acquisition of The manufacturing area at Mimest engraving, sandblasting and tumbling. University in the development and closely as possible the complex tubular materials and fatigue data”, stated features two modern Arburg injection testing of these products and remains shapes during debinding and sintering, Perina. A number of technical papers moulding machines (Fig. 9), one of hopeful that such implant components but thankfully we developed a solution by Mimest and the University of A focus on niche markets which is fitted with an automated Trento have been published at various pick-up system. The green parts are Many of the parts developed and international conferences, as well ‘Many of the parts developed and processed in a dedicated thermal produced by Mimest are not typical as in past issues of Powder Injection debinding furnace and two Italian built MIM products. The company has Moulding International. produced by Mimest are not typical vacuum sintering furnaces from TAV succeeded in developing a number SpA (Fig. 10), one of which is dedicated of unique parts for medical, high Looking ahead MIM products’ to titanium part production. There is a performance and prestige applications. small laboratory on-site that includes Sales at Mimest are currently in the Although not yet in commercial will be in commercial production in the that helped us effectively overcome this microscopy equipment and a Leco region of €500,000, however it is production, Mimest remains committed coming years. challenge”, stated Perina. Although carbon analyser. Tools are made locally hoped that with the addition of implant to its original goal of developing MIM Some of the most unique MIM production volumes were low, MIM was by independent specialists. products sales could quickly grow to parts for implant applications. Compo- components that have been produced at the time of production seen as the Fig. 10 One of two TAV vacuum sintering Mimest has the ability to manufac- €1.5 million. “We are ready to grow, nents for a knee prosthesis can be by Mimest are a range of exhaust most competitive manufacturing route, furnaces used at Mimest ture feedstock in-house, however it we believe that we have the right seen in Fig. 1. These components are components for the racing arm of a however subsequent versions of these now frequently opts to use commer- technology, the experience and the metal injection moulded from CrCoMo famous Italian motorbike manufacturer components were produced by laser elsewhere”, states Mimest. “This cially available feedstock. This is the capacity. We are confident that both the Alloy (ASTM F75). Fig. 2 shows the (Fig. 4 and 5). Manufactured from 316L, sintering. makes it even more difficult to grow case, for example, for the production medical and non-medical sides of the microstructure of the MIM prosthesis, these large MIM components were The company is flexible when it the market. First impressions of a of the titanium tripod components. business will see continued success”, and Fig. 3 gives the tensile proper- used successfully on a MotoGP World comes to minimum part production new technology are critical and when These were produced with feedstock stated Perina. numbers, particularly for specialist a customer received parts that in from PolyMIM, which Mimest state, has There remains significant potential parts such as the motorbike exhaust the past, for example, had problems brought excellent results. for MIM in Italy, however much of the components. Typical production with carbon content it is very hard “We particularly like using the feed- potential lies in the country’s large volumes, however, range from 1000 to to persuade them to take a second stock from PolyMIM, it is easy to process number of SME’s rather than larger 50,000 or more. chance”, continued Perina. and they are able to make accurate tool corporations. The challenge in this, The biggest challenge for any part factor adjustments when needed. The however, is firstly educating these producer is of course cost competitive- Titanium MIM choice of powder is also important to smaller companies to the potential of ness. Low volume MIM has proved us and for stainless steels we always MIM and secondly persuading then to to be an interesting niche market for Mimest has successfully produced a specify gas atomised powders from invest in expensive tooling. Mimest, but it does have to remain number of titanium MIM parts on a Sandvik Osprey”, stated Perina. Mimest is confident that lucrative competitive with technologies such Fig. 7 MIM titanium trigger components commercial basis. “Because of high Mimest is located on a modern markets exist. “As an example, Italy has as laser sintering. With an increase in the green and sintered state material costs, our MIM titanium technology park on the outskirts of a high number of natural gas powered in production volumes, high powder components are currently limited to Trento. “Such a facility”, states Matteo vehicles (LPG) and many cars have prices, particularly for titanium, start to extremely high value components. Perina, “gives us a great deal of flex- been converted to natural gas after have a more significant impact on the If good quality powder costs can be ibility for expansion, with the option to they were manufactured. As a result potential to develop new MIM parts. reduced, then we are certain that the quickly acquire additional space”. the tank, valves and electronics in the market will expand quickly”, stated LPG conversion kits can feature MIM Contact Perina. R&D activity parts, and there is more potential for The largest MIM titanium part that the future as environmental concerns Matteo Perina, Mimest SpA the company has produced is for the The company values its ongoing further change people’s driving habits”, Viale Dante 300, 38057 Pergine leading photographic tripod manufac- research relationship with Prof. stated Perina. Valsugana (TN), Italy Fig. 6 MIM tripod parts. In the foreground turer Lino Manfrotto + Co. SpA (Fig. 6 Alberto Molinari at the nearby Trento “Many potential users of MIM Tel: +39 (0)46153 0520 the titanium version, and in the back- Fig. 8 MIM titanium high performance and cover image). This high complexity University. “We are keen to make an components have, however, been Email: [email protected] ground the stainless steel version bicycle gears await sintering part was produced by Mimest in both ongoing contribution to the overall put off through negative experiences www.mimest.com

36 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 37

September 2010 front section new36 36 9/10/2010 12:42:25 PM September 2010 front section new37 37 9/10/2010 12:42:30 PM MIM in Italy: MIMITALIA srl MIM in Italy: MIMITALIA srl

MIMITALIA transforms the production of diamond beads using MIM processing

MIMITALIA is a small Italian producer that has adapted the MIM process

to develop a range of revolutionary diamond tool segments. PIM Fig. 2 Example of a multi-wire machine at Fig. 3 A closeup view of the EPMA Award winning diamond bead produced by International’s Nick Williams visited the company at its manufacturing work (Image Co.fi.plast. Srl, Brasil) MIMITALIA facility on the Italian Riviera and reports on progress towards its pressure to be applied only at the tip of “The potential market for such processing equipment producers”, penetration of the lucrative international diamond tool market. the bulges in the diamond tools. beads is extremely large”, Dr Risso stated Dr Vicenzi, “In the last two years, “Stone blocks can be very expensive stated. “There can be up to 40,000 however, the global recession has had and can easily be damaged by a beads on one machine, and these are a major impact and the demand for failure of the diamond beads during only expected to last for one month of such products dropped. Perhaps the the cutting process. MIM processing service”. signs are now indicating that demand has enabled us, in partnership with These products have been success- is returning”. machinery producers, to develop fully demonstrated during full scale MIMITALIA is a small specialist MIM company and during PIM Interna- up by industry. The wish to address this producer located on Italy’s Riviera tional’s recent visit he explained the was a big motivating factor behind the Production facilities coast in Vado Ligure, an industrial port motivation behind its formation. “At decision to establish MIMITALIA”. ‘The potential market for such beads close to the city of Genoa. The company CSM we were undertaking high quality MIMITALIA’s small production unit includes two injection moulding was founded in 2002 by a small group research into advanced powder based MIM diamond tools is extremely large... there can be up to of friends from Italy’s Centro Sviluppo materials, particularly materials that machines, an Arburg Allrounder 320 C Materiali SpA (CSM), a major materials related to Italy’s major hard material The new team at MIMITALIA drew on 40,000 beads on one machine’ that it used for standard part produc- research institute based in Rome. and diamond tool sectors. To our their experiences of diamond tool tion, and a smaller modified injection MIMITALIA’s Dr. Bruno Vicenzi was frustration, however, work with great processing to develop and patent a new moulding machine that is dedicated to and test new profiles that improve tests and are now in the process of one of the founding partners in the potential frequently failed to be taken method for injection moulding diamond diamond tool production. both performance and reliability. In being commercialised. “It is always cutting tools into shapes that had The company produces its own addition, MIM processing allows us to a challenge to persuade machine previously been impossible to consider feedstock in-house using a proprietary take advantage of shrinkage during builders to change to a product by the traditional press and sinter binder system. After debinding, the the sintering phase to form a very manufactured using a technology that manufacturing route (Fig. 1). This secure bond with the steel inserts they know little about. We are, however, technology received an EPMA “Award that are used to attach the tools to continually building confidence with the for Excellence in PM” in 2007 and has the supporting wires”, stated Dr Luca end user community and the perform- been a cornerstone of the company’s Risso, another of MIMITALIA’s founding ance gains and cost savings make our growth plans ever since. partners who worked closely on the offering very attractive”, continued Dr The diamond tools that MIMITALIA development of the company’s diamond Risso. has developed are primarily used tools. for the cutting of large stone (mainly The MIM diamond tools are moulded granite and marble) blocks, a major Other MIM products on a modified commercial injection industry in Italy, as well as being used moulding machine using multicavity MIMITALIA also produces a number of for the cutting of concrete. The tools moulds. Debinding is carried out via ‘standard’ MIM components in addition are in the form of beads that are then immersion in an environmentally to its range of MIM diamond tools. attached to a series of wires, 15 to 60 friendly water bath, followed by These are typically parts in stainless metres long, that form a moving cutting sintering in hydrogen at 900-1000°C and low alloy steels. Parts in produc- edge (Fig. 2). Around 30-40 beads are for 60 to 120 minutes. A typical density tion include firearms parts, spectacle required per metre of wire. of 8.5 g/cm3 (96% of theoretical) is frame components, ball screw parts, The ability of MIM to produce more reached. orthodontic items, watch straps and complex shapes than conventional PM Depending on the cutting tool cases. A selection of parts manufac- processing has brought significant design, brazing may be used to secure tured by MIMITALIA can be seen in improvements in cutting performance, the steel inserts. Currently six different Fig. 4. thanks to the ability of the beads to types of beads are in production, along “Italy has a number of smaller operate at an increased velocity. The with seven types of diamond segments industries that are particularly suited improved cutting speeds are possible for circular saw blades etc, as well as a to MIM production, such as textile Fig. 4 A selection of standard MIM Fig. 1 MIM diamond beads on sintering trays at MIMITALIA. Note that copper coated because the new geometries that number of core parts for drills. machinery manufacturers and food components produced by MIMITALIA tube inserts are used to attach the finished conical beads to cutting machinery wires MIMITALIA produces allow the cutting

38 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 39

September 2010 front section new38 38 9/10/2010 12:42:33 PM September 2010 front section new39 39 9/10/2010 12:42:38 PM MIM in Italy: MIMITALIA srl MIM in Italy: Metrocast Italiana spa

Metrocast Italiana: A leading producer of investment castings shares its experience of MIM

Metrocast Italiana is one of Italy’s leading producers of investment cast components and in the mid 1990’s the company added a MIM production line to complement its existing business. PIM International’s Nick Fig. 5 An Arburg 320 C Allrounder injec- Fig. 6 A water debinding tank for the first Fig. 7 MIMITALIA’s Gero Hochtemper- Williams visited the company in Gardone Val Trompia and discovered tion moulding machine at MIMITALIA stage of the debinding process aturöfen GmbH vacuum sintering furnace how MIM technology has been able to compete for business with its parts are sintered in a Gero Hochtem- operation, our team has a significant with its publications, but on a domestic more established rival. peraturöfen GmbH vacuum furnace. amount of materials and production level there remains a distinct lack Commenting on the facilities Dr expertise. We are able to undertake of unified MIM promotion in Italy. As Vicenzi stated, “We have the opportu- microstructural testing of finished an industry made up of many small nity to expand some of our production products, and thanks to an on- companies, it is perhaps too big a chal- to additional areas of our current going R&D programme we aim for lenge to try and do this individually”. premises, however we currently have sufficient capacity to be able to manage The steeply wooded valley that leads the currently anticipated demand ‘R&D work over the last few years is now towards the town of Gardone Val for our diamond tools. Our hope Trompia, close to the city of Brescia in is, however, that we will soon have starting to enjoy commercial success’ northern Italy, at first appears to be an sufficient demand to justify a shift to unusual area for a major metal compo- production in a continuous furnace.” continuous technological innovation. MIMITALIA also took part in a nent manufacturer such as Metrocast “Although we are a very small This also helps us to diversify into new EU funded project on modelling of Italiana to be located. When reaching markets – the more legs that we have moulding and developed a large part Gardone Val Trompia, however, the the more chance that we can remain of the MIM course lessons within the name on the walls of the largest factory standing in the future!”, stated Dr “DesignForPM” (www.designforpm.net) in the town explains all, “Armi Beretta”. Vicenzi. e-learning project. This most iconic of Italian firearms Much of the R&D that has been manufacturers was established in the undertaken at MIMITALIA has been Outlook town in 1526 when gunsmith Maestro within EU, national and regionally Bartolomeo Beretta first supplied funded programmes. These have The team at MIMITALIA indicate that weapons to the Arsenal of Venice, and included the production of titanium their R&D work over the last few years the town has been the heart of Italy’s parts, “We have successfully manu- is now starting to enjoy commercial gun manufacturing industry ever since. factured titanium MIM components”, success and that the major interna- Today a large number of firearms continued Dr Vicenzi, “but our lack of tional market for diamond tools is manufacturers are located here, a second sintering furnace means that finally opening up to the potential of producing weapons that range from Fig. 1 Investment castings being manufactured at Metrocast Italiana we have to have parts sintered by a products produced by the MIM route. pistols to traditional shotguns. third party”. The company predicts that a consider- It was to serve the market for gun SpA, can still be purchased today. some Ni-hard alloys. Today Metrocast able proportion of its diamond tool components that investment castings Metrocast Italiana was one of the Italiana employs over 50 people at its products will be exported to China producer Metrocast Italiana was first Italian companies to offer invest- 6000m2 factory. Turnover in 2008 was Technology awareness within one year. established in 1967. A family enter- ment casting technology and within a in the region of €9 million, although As current Co-Chairman of the Euro- prise, the cousins Marco and Antonio few years it became a leading producer only a small percentage of this relates pean Powder Metallurgy Association’s Contact Sabatti today run the business that was of castings for the shotgun market. The to MIM. (EPMA) EuroMIM sectoral group, Dr founded by their fathers. company, however, diversified into new Vicenzi is well aware of the challenges MIMITALIA Srl The Sabatti family has for several sectors, from the automotive industry The move to MIM facing the MIM industry as a whole, Via alla Costa 24, 17047 Vado Ligure centuries been part of the long to food processing, packing and textile particularly that of marketing MIM. “It SV, Italy tradition of gunmaking in Gardone machinery. In 1995 the company took the decision is essential for the development of the Tel: +39 019 210 0089 Val Trompia, starting with Ludovico The main material investment cast to invest in MIM production, becoming Fig. 8 Diamond beads before sintering. industry for technology promotion to Fax: +39 019 216 1574 Sabatti in the early years of the 18th by the company is steel, however all the first Italian component manufac- Shrinkage during sintering forms a tight be increased. The EPMA has supported Email:[email protected] century. Sabatti shotguns from the air meltable nickel base or cobalt turer to offer the technology to external fit with the steel inserts the industry on a pan-European level www.mimitalia.com family’s gun making business, Sabatti base alloys are available, as well as customers.

40 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 41

September 2010 front section new40 40 9/10/2010 12:42:47 PM September 2010 front section new41 41 9/10/2010 12:42:50 PM MIM in Italy: Metrocast Italiana spa MIM in Italy: Metrocast Italiana spa

An insight into competing production methods “As long as Metrocast Italiana has two manufacturing technologies, we can offer our customers the most suitable solution. It is, however, important to realise that the two technologies suit different kinds of parts, and a compo- nent is rarely economically feasible through both MIM and investment casting. On occasions where parts are suited to both processes, we will of course quote for both. As a rule, however, if an investment cast part does not need any secondary machining, it is usually cheaper than MIM.” Due to the high tooling costs, Metro- Fig. 2 Investment casting assemblies being coated with dry Fig. 3 Investment cast parts with their refractory shell partly cast suggest that economically viable refractory particles following dipping in a refractory slurry removed volumes for production by MIM typically “In the early 1990’s we saw MIM moulding machine and batch furnaces The challenge of selling exceed 20,000 parts per year. The attracting the interest of many of our from Gero Hochtemperaturöfen and MIM technology minimum batch for investment casting customers and we did not want to risk Cremer Thermoprozessanlagen. is usually around 500 parts, depending losing out to a competing technology. Thanks to its existing investment Whilst the MIM facility did succeed in on size and complexity. A major Fig. 5 Furnaces at Metrocast Italiana: Left, a Gero Hochtemperaturöfen debinding We therefore researched the process casting operation, the company attracting customers, Antonio Sabatti difference is of course component size, furnace and right, a Cremer Thermoprozessanlagen sintering furnace commented that the expected rush with investment casting being able to towards MIM processing by potential manufacture parts ranging from 1 g poor. This is compounded, however, MIM, proposing the most competitive ‘Our customers were excited customers in Italy did not materialise to 5 Kgs. Metrocast Italiana is today by the nature of Italy’s economy, “Our process to the customer. Existing about MIM, but when it came to as expected, “During the 1990’s I think focusing on the production of smaller economy is quite special in that it has a investment cast parts are rarely trans- we and many others assumed that ferred to MIM, but we see new designs production volumes, they were often not MIM would take much more business as having a much higher chance. There from the investment casting industry ‘Our advantage is that we can is also the benefit that MIM parts are quite high enough to justify a move away than turned out to be the case. The generally quicker to manufacture”. problem was to a great extent part offer customers both investment from investment casting’ volumes. Our customers in the Contact firearms industry were excited about casting and MIM’ and the potential markets and made already benefitted from well equipped MIM and trusted the technology, but Metrocast Italiana S.p.A. the decision to invest in MIM”, stated metallographic testing facilities. In when it came to production volumes and more complex MIM parts where high reliance on SME’s, many of which Via Valtrompia 121, 25063 Antonio Sabatti. August 2000 Metrocast Italiana was they were often not quite high enough the process is most competitive. are family owned. Persuading such Gardone V.T. (Brescia) Italy The company invested in a produc- certified to ISO 9002 standards for to justify a move away from investment “The market for components, smaller companies to invest in tooling Tel: +39 030 831437 tion facility that uses BASF’s Catamold both its investment casting and MIM casting.” especially for the firearms industry, that costs several thousand Euros is Fax: +39 030 8911166 feedstock system: an Arburg injection operations. “Gun production volumes are not is today more competitive than it ever difficult”, stated Antonio Sabatti. Email: [email protected] always high and designs can change has been. For a while a large Indian “Our advantage is that we can offer www.metrocast.it frequently. So the requirement for high MIM producer had a sales office here, customers both investment casting and volumes combined with expensive but in reality the part volumes that the tooling meant that the MIM technology local market required were too low to did not take off with the speed that we make business attractive, even with would have liked”, continued Antonio the lower cost-base in India. Machining Sabatti. is also a threat, especially in these The company today produces MIM hard economic times. Small Italian parts for firearms and other markets machining workshops are desperate such as textile machinery components for business and are cutting prices from low alloy steels, stainless steels, to the limit. As a result some lower tool steels and soft magnetic alloys. volume MIM parts are now machined, Approximately 25-30 new tools are but this situation is not sustainable”, added each year, with the domestic suggested Antonio Sabatti. market accounting for 80% of production. The outlook for MIM in Italy The biggest challenge for Italian MIM producers, states Antonio Sabatti, is that awareness of MIM remains very Fig. 4 A view of the MIM facility at Metrocast Italiana Fig. 6 A selection of MIM parts produced by Metrocast Italiana

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September 2010 front section new42 42 9/10/2010 12:42:57 PM September 2010 front section new43 43 9/10/2010 12:43:04 PM GKN Sinter Metals: All eyes on non-automotive Web-based marketing Web-based marketing opportunities for All eyes on Non-Automotive: opportunities for the GKN Sinter Metals explores MIM & CIM producers PIM industry the wider opportunities for MIM

The term ‘non-automotive’ remains a closed book for many of the world’s larger MIM producers, particularly those located in Europe where the automotive industry was quick to embrace MIM technology. GKN Sinter Metals is one such producer that is now re-evaluating the potential of the non-automotive market. In the following report, the company presents an insight into the opportunities ahead and explains, based on its own experiences, what it believes is important when dealing with non- automotive customers.

GKN PLC is one of the most well known technology suppliers to the global Every year a growing number of end-users automotive industry and the group’s PM division, GKN Sinter Metals, is one make use of www.pim-international.com of the industry’s largest producers. Within GKN Sinter Metals, the Bad Langensalza plant in Germany is one of the highest capacity MIM operations in Increase your web presence with the world. PIM International Although Bad Langensalza was visitors anticipated in 2010, originally established in 1967 as www.pim-international.com is the leading on-line resource 40,500 based on 1st Quarter 2010 a producer of press and sintered for the MIM and CIM industries. We provide our international components for the East German traffic typewriter industry, the business has in audience with extensive technology features, industry news, event recent decades been dominated by the guides and pay-per-download access to all previously published page loads anticipated in 2010, automotive industry. features and technical papers from PIM International. 100,000 based on 1st Quarter 2010 traffic The term ‘non-automotive’ has, therefore, only gradually become adopted to define a specific part of the Solutions for part producers pages of content, with more being MIM business at GKN Sinter Metals, Fig. 1 Regional distribution of MIM market segments as seen by GKN Sinter Metals and it is a description that market For PIM part producers in particular, marketing to a diverse added every month 450 participants themselves introduced as markets into four sub-markets, namely with a 43% share of the market. range of end-user sectors can be a major challenge. Key sections a simple way of identifying all products industrial, consumer, IT/electronics Even in Europe, however, the sum of our website have been specifically designed with the promotion that are not directly related to the auto- and medical. of all the non-automotive segments of PIM technology in mind. We attract a significant number of motive industry. This sector includes, When looking at the major regional dominates with a 57% market share. end-user visitors, including major international electronics, of course, innumerable sub-markets, MIM markets in Europe, Asia and GKN Sinter Metals reflects this trend since there are many more opportuni- North America, the non-automotive based on its share of non-automotive automotive engineering and aerospace corporations as well as automotive engineering and aerospace corporations as well as ties for applications of MIM products segments, considered in their entirety, products as compared to the total numerous OEM’s and SME’s. outside the automotive industry than dominate everywhere (Fig. 1). The business. Already, for a number of there are inside. automotive segment, in contrast, years, a continuously slower growth For further information To allow for a broad approach, GKN becomes less important every year. in the automotive business has been Sinter Metals adopted a meaningful Only in Europe are automotive applica- observed in contrast to a faster growing Contact Jon Craxford: Tel: +44 (0) 207 1939 749 Email: [email protected] segmentation of the non-automotive tions still the strongest single segment non-automotive business.

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September 2010 front section new44 44 9/10/2010 12:43:12 PM September 2010 front section new45 45 9/10/2010 12:43:14 PM GKN Sinter Metals: All eyes on non-automotive GKN Sinter Metals: All eyes on non-automotive

The MIM non-automotive business Non-automotive markets case, technology shifts, where MIM A typical customer portion of the traditionally automo- need new ideas to develop takes a component from a competing discovering MIM tive dominated GKN Sinter Metals technology. is already at 20% and will probably further technology double again over the next three to The automotive and non-automotive This approach is particularly beneficial four years. MIM businesses are fundamentally Medical technology: A to improve customer relationship, as different to one another, particularly market segment with a is well demonstrated by the following in their customer base. bright future case study. Otto Bock Health Care One can assume that today the GmbH, a manufacturer of medical majority of automotive customers Medical technology is clearly among devices, has been an integral part of has examined in detail both the the non-automotive market segments the established customer base of GKN viability and cost-effectiveness with the strongest growth potential. Sinter Metals, with regular supplies of MIM technology, as well as its Both the technology itself and the of conventional press and sinter PM competing technologies, and accept range of MIM materials applied are parts. In 2009 GKN Sinter Metals that they are generally open-minded constantly improving. OEMs are organised a technology day (TechDay) towards MIM. In the non-automotive becoming ever more aware of the in the R&D Center of Otto Bock in sector the situation is generally capabilities of MIM and they explore order to give the engineers on site a different. Although there are typical ways to convert their components comprehensive insight into the entire non-automotive markets where to MIM technology in order to process spectrum of PM technology. MIM already plays an important and both enhance the performance of This event proved a great success as Fig. 4 Stretching unit with twin connecting plate central role as a manufacturing their products and reduce their it succeeded in raising Otto Bock’s technology (for example the firearms manufacturing costs. awareness of the advantages of MIM and watchmaking industry), the MIM medical applications today technology. The process was already potential of MIM technology is not yet exhibit an extremely wide variety known to the engineers of Otto Bock, but they had never really considered actual applications because the ‘there are still unexplored MIM markets benefits were not known to them in detail. with applications whose potential is It can be observed again and again that the level of knowledge about MIM still unknown, both for the consumer technology amongst design engineers and the producer‘ and end-users is still, unfortunately, very low. Educational work is therefore more important today than ever, Fig. 2 New artificial limb „3R93“ by Otto sufficiently recognised in many other of shapes and sizes. They range however it can only have a lasting Bock with integrated brake and blocking industries, and design engineers from surgical instruments such as effect if all MIM manufacturers commit function need support from parts suppliers. scissors, scalpel handles or other themselves to the task of increasing Therefore MIM parts manufacturers instruments to prosthetic devices the awareness of MIM technology. still need to do the basic development (Figs. 2 and 3), orthopaedic bodies Steffen Sawatzki, Head of the Fig. 5 GKN Sinter Metals MIM parts for Otto Bocks prosthetic knee joint (blocking work for them. If they succeed in and even hearing aids. The more MIM Prosthetic Knees and Hip Joints plate, blocking hook and twin connecting plate) helping develop new applications, evolves technologically, the smaller Division at Otto Bock, still remembers today’s non-automotive market could medical devices become. This trend which benefits were ultimately crucial be seen as only a fraction of what it is clearly noticeable in micro-MIM for him and his development team to the shift to MIM technology required a see many potential applications for the could be in the future. applications that will also play an opt for MIM technology. “With the MIM reorientation for his development team. MIM process within the wide range of The constant strong growth important role in the medical sector. process our designers have more crea- “You need to start thinking differently products produced by the company. For reported by the MIM industry over Even though the MIM process tive freedom, thus entirely new avenues when you apply a shaping process like the first approach they did not want to many years has mainly been the is well established in the medical for part design open up the possibility result of common efforts by market sector, a significant proportion of for product innovation. At the same participants who are constantly in companies can still be found that are time compact and sophisticated metal ‘MIM materials simply offer a more search of new applications for MIM unaware of the technology. In this part design has also clear advantages homogeneous material structure products. The non-automotive busi- context, the importance of sales and in terms of production costs. Another ness as we know it today is defined marketing expertise should not be strong argument for us was the possi- which dramatically improves the by the known demand for MIM parts underestimated. Dr.-Ing. Rainer Link, bility of reducing secondary operations, that is already served by the industry GKN Sinter Metals Senior Vice Presi- which in turn also saved time and technical characteristics of products worldwide. Beyond that, however, dent stated, “At GKN Sinter Metals cost. And beyond that MIM materials are unexplored MIM markets with we are aware of this challenge. In simply offer a more homogeneous made out of them‘ applications whose potential is still addition to a desire to continuously material structure which dramatically unknown, both for the consumer and acquiring new customers, which is improves the technical characteristics the producer. naturally a core part of our sales of products made out of them.” the injection moulding of metal parts convert existing components to MIM, These could be innovations and marketing strategy, we closely In the past, alternative production rather than a machining process. The but rather draw on a new product (applications that did not exist before monitor our existing customer base methods such as milling and invest- design of freely formed surfaces must development. The MIM components and will be first implemented in ment casting were predominant at Otto be intensified.” that are manufactured today by GKN Fig. 3 Detail of 3R93, a prosthetic knee with the aim of finding potential MIM) or, which is most frequently the Bock. Steffen Sawatzki explained why Otto Bock’s development engineers Sinter Metals for Otto Bock GmbH are joint synergies.”

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September 2010 front section new46 46 9/10/2010 12:43:17 PM September 2010 front section new47 47 9/10/2010 12:43:22 PM GKN Sinter Metals: All eyes on non-automotive GKN Sinter Metals: All eyes on non-automotive

a blocking plate, blocking hook and a ments that the components have to Otto Bock Health Care improvement of materials for more twin connecting plate (Figs. 4 and 5). meet. “All three components must GmbH safety and comfort. For a successful They are used in the new prosthetic guarantee a completely safe operation future the company will continue to knee 3R93 (Fig. 3). The blocking plate because patient safety is the priority. Products from Otto Bock, as solutions look for innovative solutions such as and blocking hook are assembled However, that is not all. In addition for people with limited mobility, have electronically controlled prosthesis and together in the knee joint as a unit. to excellent corrosion resistance and set the highest standards and improve orthosis systems and products made They are used to prevent accidental high mechanical strength, an attractive the quality of life of physically disabled by high-end technologies. variable knee flexion when necessary surface appearance of both visible and people every day. The company is as a protection of the knee joint. In this invisible parts is expected.” now the leading supplier of innovative The story of GKN Sinter case the blocking hook, which is rotat- In order to support the future products for people with restricted able, snaps in on the blocking plate in adoption of the MIM process in the mobility and the global leader in Metals GmbH the extended position and blocks the development of new products, the orthopaedic technology. The Otto Bock GKN Sinter Metals GmbH Bad flexion of the prosthesis. When the successful implementation of the first Health Care product range is based Langensalza is one of the world’s on the objective of restoring patient leading producers of MIM components. ‘With our supplier GKN Sinter Metals mobility and protecting the functions The company history dates back to they have retained. It is divided into 1967 when the plant, at that time TM we have found a competent partner in the Orthobiontic line, which includes under the umbrella of the East German prosthetic and orthotic solutions, Robotron Group, produced typewriter Fig. 7 A view of GKN’s Bad Lagensalza MIM facility showing continuous debinding and TM our vicinity who vigorously supported us and the Bionicmobility line (Fig. 6). parts by the press and sinter route. sintering furnaces This includes mobility solutions with After the political turn-around in already achieved a great deal towards in establishing our products‘ a broad range of manual and power Germany a difficult restructuring the realisation of this objective. As part wheelchairs on the one hand and the phase began which found the plant of the ‘Market champions’ initiative field of neuro-stimulation on the other being incorporated into the GKN Sinter of the German State of Thuringia, our blocking hook is lifted in the extended three components of the knee joint hand. Metals Group, a sub-division of the MIM plant in Bad Langensalza was position of the prosthesis by means of prosthesis will be publicised within Otto In terms of quality, user safety is the UK listed GKN plc (www.gkn.com). In appointed the market and technology a lifting device, the flexion of the knee Bock. According to Steffen Sawatzki, key issue. Mechatronic leg prosthesis 1996, the introduction of the innovative leader in Metal Injection Moulding. The prosthesis is activated and the patient more components are currently in a systems minimise the risk of falling. MIM process created the basis for project is supported by the Thuringian can sit down, for example. feasibility study and a transition to Modern orthoses improve the success employing a workforce of currently Ministry of Economy, Labour and The twin connecting plate has MIM is in preparation. “The benefits rate of treatments such as surgery by more than 100 people. Technology and the award confirms two functions. First it serves as a demonstrated by these examples, providing protection against excessive In 2003, around €7 million was that GKN Sinter Metals now already protection against accidental reaching just in terms of production cost and strain without unduly inhibiting the invested in additional machinery, belongs to the top three MIM producers into the joint mechanism, and on design options, will also be considered patient’s mobility. equipment and buildings at the in Europe. Our certifications to the the other hand it is required for the in future projects. With our supplier Otto Bock regularly enters popular company location in Bad Langensalza environmental standard ISO 14001 as power transfer and connection of the GKN Sinter Metals we have found a cross-sector design competitions (Fig. 7). The main products of GKN well as TS 16949 and OHSAS 18001 prosthetic knee stretching device when competent partner in our vicinity who and has won numerous awards for its today are primarily components for show that the intentions were put into the knee is bent or stretched. vigorously supported us in establishing product design. The company expects the automotive industry, however practice.“ Demands on the three components our products. Thanks to the short a great future potential in the develop- there is an ever growing proportion of For the achievements in the field of are very high. Steffen Sawatzki distance to our contact partners we can ment of prostheses with biofeedback non-automotive applications. Quality corporate quality management GKN Fig. 8 Dr.-Ing. Rainer Link, GKN describes in detail the specific require- solve all problems quickly and easily.” mechanisms, and in the continuous is of most importance at GKN Sinter Sinter Metals GmbH, in addition to the Sinter Metals, Senior Vice President, Metals, as well as further technical award mentioned above, received the Engineering, Sales & Marketing development. A substantial part of the Thuringia State Award for Excellent investments made in recent years were Quality. the successful cooperation with the spent in the area of quality assurance. Dr. Link continued, “MIM is a company Otto Bock.” “Our activities are subject to high fascinating technology where we have standards of quality and efficiency already important automotive applica- Contact and our actions are strictly oriented tions, for example in turbocharger towards the protection of our environ- systems. The global non-automotive GKN Sinter Metals GmbH ment,” stated Dr. Andreas Kubosch, market is complex and challenging, but Am Fliegerhorst 9 Plant Manager at GKN Sinter Metals. offers a huge number of opportunities 99947 Bad Langensalza, Germany GKN Sinter Metals is committed to for growing the GKN Sinter Metals Tel: +49 3603 8959-0 become the market leader among the MIM business in the future. We are Fax: +49 3603 895999 European MIM manufacturers. Dr.-Ing. prepared for joint developments with Email: [email protected] Rainer Link stated, “This year we have our customers as demonstrated by Web: www.gknsintermetals.com

For in-depth coverage of the PIM industry.... It costs only £95 to benefit from more than 250 pages of exclusive news, special reports, features and technical papers Fig. 6 Otto Bock Health Care GmbH is a global market leader in the manufacture of solutions that restore patient mobility and each year. Subscribe today using the form on page 71 protect the mobility functions they have retained

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September 2010 front section new48 48 9/10/2010 12:43:24 PM September 2010 front section new49 49 9/10/2010 12:43:31 PM Back to basics: handing and testing green parts Back to basics: handing and testing green parts

Back to basics: from the

injection moulding machine Radiation source to the debinding oven Source container

Test part height h Raw materials undergo several transformations during the metal Cross-section d injection moulding process, from powder through to feedstock, the Aperture production of the green compact, debinding and finally sintering. Fig. 2 Green MIM parts being deposited on a conveyor belt (courtesy Arburg) In this latest part of our back-to-basics series, Dr Georg Schlieper Detector focuses on green compacts and the methods used to characterise their properties, as well as green part processing and handling.

He / N 2 P Sample Expansion chamber chamber Fig. 4 Design principle of the gamma ray   densitometer (courtesy Gammatec)

Gas Inlet Gas outlet compact is an indication of the powder- When we look at the stages between apply as many intelligent tests as injection moulding machine. There to-binder ratio, and the highly dynamic injection moulding and debinding, possible to eliminate defective parts in are a number of options and it has to conditions during mould fill can lead to Fig. 3 Principle of gas pycnometry (courtesy Micromeritics) we should consider the separation the green stage before they go through be decided which one is the best both undesirable effects such as the separa- of parts from runners and sprue and the costly debinding and sintering technically, for a high product quality, tion of binder from the powder. discharge from the moulding machine, process. One focus of this feature will and economically, for the lowest reduces the tooling costs, but green inspection area or the next processing The result is a local density gradient inspection, characterisation and quality be on testing green MIM compacts. possible manufacturing costs. parts are released from the mould step can be achieved automatically by in the green compact which leads to with sprue and runner attached to using conveyor belts, or parts can be distortion after sintering. Knowledge Intelligent mould design them. Therefore they must be sepa- manually collected and arranged on of these effects and how to avoid them ‘The essential preconditions for a high can help to improve the dimensional saves handling costs rated mechanically and possibly the trays. product quality and economic efficiency gate marks must be trimmed manually. accuracy of MIM parts. A great deal can be achieved though This causes extra time and costs. The characterisation of of the MIM process are set during intelligent mould design, in terms of A more sophisticated approach is a green parts The Archimedes test both part quality and economic green sub gate. Here the feedstock is injected Overall density can be measured injection moulding’ part handling. The mould type, the through a short channel in the cavity Part weight by one of the traditional methods type of gating and the precision of the plate and the runner is automatically A very important and easy to measure such as the Archimedes test or gas mould have a distinct effect on the way sheared off when the part is ejected. characteristic of green parts is their pycnometry. For the Archimedes test, control of green parts, green parts The first issue to be solved after the parts are released from the mould, The parts can be caught in a basket weight. Installing a fully automatic ie the determination of the volume manual processing or machining, as injection moulding is how to separate and on the number of secondary when they fall off the mould separately balance for 100% weight control by measuring buoyancy in a liquid, a well as handling and transport to the the sprue and runners from the parts, operations required. from sprue and runner or taken out by is inexpensive and the statistical minimum sample volume of 1.5 cm³ debinding process. and how to remove the parts from the A simple tap gate design (Fig. 1) a picker arm. evaluation of the part weight provides is required, corresponding to a part The essential preconditions for a If a three plate tooling is used, valuable information about the stability weight of 7 to 8 g for ferrous alloys high product quality, and the economic the gate is integrated in the cavity of the injection moulding process. in the green state. If the part weight efficiency of the MIM process, are set plate. Then sprue and runner fall out Many possible flaws in green is lower, which is often the case in during injection moulding. The green separately from the parts. compacts such as cavities, incomplete MIM, several parts should be tested compact is the first intermediate The hot runner mould is the most mould fill, binder separation and together. Then, of course, the result product in the process that has expensive type. Sprue and runners others are reflected in the part weight. is the average density of the tested essentially the shape of the final are kept in the molten state all the Automatic optical inspection with parts. component and that allows it to be time and only the parts cool down cameras may also be applied to detect Another difficulty may be caused tested for product quality. Any defects and are ejected. In this case there are surface defects at critical points. by the binder. If solubility of the binder or irregularities in the green compact no runners at all and the costs for in the liquid used for measuring the

will still exist in the sintered product. Tap gate Sub gate 3 plate tooling recycling sprue and runners are also Density volume exists, the Archimedes method Sintering leads to a consolidation of saved. Besides the weight, the density is a is not applicable. Obviously parts the powder, but it does not ‘heal’ any Fig. 1 Gate options in mould design: tap gate (left), sub gate (middle), and three plate The transportation of parts from key property characterising green containing a water soluble binder defects. Therefore it is important to tooling (right) (courtesy Dynamic Engineering, USA) the injection moulding machine to an compacts. The density in a MIM green should not be immersed in water.

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September 2010 front section new50 50 9/10/2010 12:43:32 PM September 2010 front section new51 51 9/10/2010 12:43:34 PM Back to basics: handing and testing green parts Back to basics: handing and testing green parts

parts. Therefore the use of vacuum is becoming more and more favoured. The application of sucking pickers (Figs. 2 and 9), however, requires a flat surface to seal the picker orifice. Magnetic pickers are also applied for ferromagnetic materials.

Summary The processing methods applied in MIM are very diverse and in many cases manufacturers have developed proprietary methods of handing and Fig. 7 Robotic handling systems. Left - Robot reaching into an injection moulding processing parts between the injection machine (courtesy Reis Robotics, USA Inc) Right - Overhead-mounted robot (courtesy moulding and sintering stages. For FANUC Robotics America Inc.) reasons of confidentiality some of the most interesting of these cannot be mould parting lines if they cannot be Robotic arms (Fig. 7) are the most reported. It is hoped, however, that tolerated on the finished part. universal systems offering virtually this article has given a useful overview Sometimes it is more economical unlimited freedom of movement of this important stage of the MIM Fig. 5 Densitometer used in the press and sinter industry (courtesy Gammatec) Fig. 6 X-ray images of tensile test bars green (left) to keep the mould simple and machine including rotation, but the XYZ systems manufacturing process. and sintered (right) (courtesy IFAM Bremen) certain features and geometrical (Fig. 8) are often faster and have a Gas pycnometry are available in this respect: gamma constant within the aperture area. This details such as threads on the green higher accuracy when positioning Author An alternative method is gas pycnom- ray densitometry and image X-ray is the most severe restriction of this compact. Most MIM feedstocks have parts. etry. This measures the volume of radiography. method. Surface areas with a strong sufficient green strength to allow Robotic arms seem to be better Dr. Georg Schlieper the sample through the displacement inclination or variation of the thickness machining operations. In this case the suited for removing large parts from Ingenieurbüro Gammatec of helium gas in a container whose Radiographic inspection are not accessible by this measure- parts are subsequently cleaned and an injection moulding machine, and Mermbacher Str. 28 volume is known with the highest ment. Fig. 5 shows a densitometer for sharp edges and burr are removed by XYZ systems are advantageous for D-42477 Radevormwald possible precision. The sample is The local density can be measured the PM industry. brushing or mild sand blasting. placing parts in an orderly manner on Tel: +49 (0)2195 6889274 placed in one of two chambers, then in a small volume of the compact X-ray radiography generates images trays as a preparation for the debinding e-mail: [email protected] the sample chamber is filled with without destroying it with a gamma of the test parts which allows detec- Automatic green part process. www.gammatec.com helium gas which is expanded into the ray densitometer. It measures the tion of defects in the entire part at a handling systems Depending on the green strength expansion chamber (Fig. 3). The pres- intensity of gamma radiation after glance. Fig. 6 shows a tensile test bar of the binder system and complexity sure drop due to the volume expansion being weakened by the test part. in the green state and in the sintered The MIM process is an effective of shape, MIM green parts can be very Related content state. The green compact contains manufacturing technology for delicate. Automatic parts handling New methodology of resonant fine bubbles in the middle section high volume part production. Such systems must take account of this. inspection applied to MIM parts ‘the injection moulding technology which lead to severe distortion during technologies, however, call for process Besides the type of positioning system, Richard W. Bono, The Modal Shop sintering. automation in order to maximise the choice of picker is important. The probably offers the greatest design Inc., USA. PIM International Vol. A thorough knowledge of the density efficiency and the market offers a wide picker must grip and hold the parts 4 No. 2 p 53-56. Now available to variations in a green MIM compact variety of automatic parts handling securely and release them at the new freedom of all parts manufacturing download from the PIM International is important because the amount of systems. There are two basic types of position. Mechanical pickers must be PDF store. shrinkage depends very much on the handling systems available: robotic specifically designed for each part in processes’ www.pim-international.com local density. The shrinkage during arms and XYZ pick-and-place systems. order to reduce the risk of damaging serves to determine the sample volume The principle of radiographic density sintering leads to the densification of based on the ideal gas law. measurement is shown in Fig. 4. A the material. Pores due to air bubbles A high accuracy of ±0.01% can be radiation source inside a shielding or removed binder are eliminated and achieved with this test as long as the container produces a beam of gamma the amount of shrinkage is higher sample volume occupies at least 10% radiation of a well-defined energy and where the material has more porosity. of the chamber volume. The optimum constant intensity. The radiation passes This causes a distortion of the part, as condition is achieved if the sample through the test part and an aperture. can be clearly seen in the tensile bar. fills two thirds of the sample chamber. The absorption of this radiation inside Sample chambers of different volumes the test part is measured. Secondary operations on are available ranging from 0.1cm³ to The density measurement includes green parts 2000cm³. If the sample volume is too a measurement of the material small, several parts may be tested at thickness at the test point. The volume Although injection moulding technology the same time and the result is then in which the density measurement is probably offers the greatest design the average density. taken is given by the cross-section of freedom of all parts manufacturing Again the pycnometer is only able the aperture and the material thick- processes, there may be secondary to measure the average density of ness within this area. In favourable operations necessary on green MIM the sample. For a measurement of cases the aperture may be as small as parts. One reason has already been sectional densities or density gradients 1mm diameter, but the test requires mentioned - gate marks may have to it is necessary to use radiographic that the part covers the entire aperture be sheared, cut or milled manually or methods. Two alternative methods and that the thickness is reasonably automatically. The same applies for Fig. 8 XYZ pick-and-place system (courtesy Bahr Modultechnik) Fig. 9 Sucking picker holding a sheet (courtesy MM Engineering)

52 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 53

September 2010 front section new52 52 9/10/2010 12:43:36 PM September 2010 front section new53 53 9/10/2010 12:43:40 PM mim2011 ad_Layout 1 9/8/2010 12:31 PM Page 1

Higher efficiency MIM furnaces REGISTER BY FEBRUARY 11 AND SAVE! Higher efficiency MIM furnaces through new materials and design solutions

Make plans to attend the only international The metal injection moulding process can be extremely demanding on sintering furnaces and related fixtures and supports. High metal and powder temperatures, combined with the presence of binder systems, can lead to a rapid deterioration in furnace performance and efficiency. injection molding event Dr. Bernd Kleinpass, from PLANSEE Metall GmbH in Austria, explores of the year! some of the main problems and the solutions that are now available.

MIM2011 CONFERENCE The furnace requirements for the Since MIM is a steadily growing an integrated debinding and sintering (March 15–16) sintering of metal injection moulded market, furnace manufacturers have process whereas other equipment (MIM) parts are extremely demanding. developed unique concepts for their manufacturers prefer separate, A two-day event featuring presentations and a keynote luncheon Temperatures can range from 1200°C sintering furnaces. Most of these more specific equipment for these to 1600°C, with the need for a high concepts use molybdenum all metal two processing steps. Additionally, degree of temperature uniformity hot zones, molybdenum heating a number of different approaches to • Focus on manufacturing best practices and a controllable environment, from elements, and molybdenum carrier and debinding exist, one of which requires vacuum over partial pressure using handling hardware. the use of a catalytic agent. • Leading process trends different gases to pressurised cooling, In the sintering process both batch Sintering takes place either in for example. Cleanliness is also and continuous furnaces are used vacuum, nitrogen, hydrogen, argon • Numerous case studies critical because of thermal debinding, depending on the production volume, or mixtures of these atmospheres. the frequent presence of catalytic product size, and material and quality Continuous furnaces are operated • Tabletop Exhibition & Networking Reception agents, and the need to avoid carbon requirements. Continuous furnaces with a slight overpressure while with representatives from many of the contamination. Furnace durability is may be pusher or walking beam by batch furnaces often operate in additionally impacted by economic design, and both systems can be partial pressures down to 10 mbar or leading companies in the field factors that demand high yields, automated to increase production less in order to support the thermal volumes. Some furnace systems use debinding. ...and much more! resulting in the dense packing of parts.

Optional One-Day Taught by Randall M. German, world-renowned PIM expert Powder Injection An ideal way to acquireacuire a solid grounding in powder injectioninection molding Molding Tutorial technology in a short period of time Precedes Conference • Introduction to the manufacturing process • Definition of what is a viable PIM or MIM component (MarchMarch 14) • Materials selection and expectations • Review of the economic advantages of the process

Fig. 1 Molybdenum coating on ceramics due to oxygen contamination (left) and deformation of molybdenum heating elements due to Thishis conference is sponsored by the Metal InjectionInection Molding Association,Association a trade association carburisation (right) of the Metal Powder Industries Federationederation Visit mimaweb.org or mpif.org for complete program details and registration information 54 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 55

September 2010 front section new54 54 9/10/2010 12:43:41 PM September 2010 front section new55 55 9/10/2010 12:43:42 PM Higher efficiency MIM furnaces Higher efficiency MIM furnaces

sintering. At the same time the MIM- Batch Continuous 1200°C to 1300°C box might also work as a multi-tier rack with supports for the charging plates. The design and material selection for the MIM box should give dimensional integrity and allow for even gas distribution during long periods of operation. MIM furnace manufacturers and companies who engineer and manufacture replacement hot zones have experience in the design of MIM boxes that will perform and operate efficiently in all operating conditions. Fig. 5 shows a MIM box which was installed in an existing MIM furnace as an OEM replacement. The rigid Fig. 2 MIM Furnace components made of molybdenum based Fig. 3 Example of charging assembly in continuous furnaces double wall structure is constructed materials using MLR material (doped Molyb- denum) that enables the MIM part producer to increase the load volume of the furnace, reducing sintering and Fig. 5 Replacement MIM box with optimised load capacity operating costs. Charging plates slide either into a multi-tier rack MIM box or are stacked • Heating elements resist sagging The sagging behaviour of different between spacers; each plate thickness and distortion molybdenum materials can be seen is between 1 mm to 3.17 mm and uses • Radiation shielding is less likely in Fig. 6. Although TZM has superior alumina to separate the MIM parts to break. strength and creep properties from the molybdenum plates. Most of these components typically compared to pure molybdenum, it does The charging plates can be coated last the life of the hot zone with little not attain the same performance of with a ceramic layer which works need, if any, for spare parts. ML at the high temperatures typical like a separation plate. Depending on ML molybdenum is an alloy where for MIM even though it is still used by the furnace condition and MIM part doping with lanthanum oxide particles OEM’s in their equipment design for material, different oxide ceramic with and a sophisticated thermo-mechan- charging plates and heating elements. varying compositions can be applied, ical treatment during production lead An example of a re-designed hot Fig. 4 Carrier devices used in MIM furnaces e.g. alumina, zirconia, titanium dioxide to an extremely stable microstructure zone replacement using alternate and yttria. Besides the time and cost with elongated grain structure and materials like ML is shown in Fig. 7. Low partial pressures can lead place due to non-uniform material furnaces (Fig. 3) consists of a bottom saving resulting from the lack of neces- jagged grain boundaries. As a result, The deformation of the charge plates to the problem of plasma arcing at properties (Fig. 1, right). carrier component and several stacked sity for ceramic separation plates, the the creep resistance is excellent to (left image) had reduced the loading high temperatures between heating intermediate plates that are spaced by total weight of the charging devices is temperatures of 1850°C, and ML capacity of the furnace having a nega- elements and element supports or alumina or molybdenum rods. Fig. 4 reduced, leading to higher load capacity retains its ductility after exceeding tive impact on the dimensional toler- shielding, in particular when argon is Molybdenum products in shows two examples of carrier devices and lower energy demand. these operating temperatures. ance of the MIM parts. A new hot zone used as the process gas. Such arcing MIM sintering furnaces used in continuous MIM furnaces. can result in metal coating of the The bottom carrier may be molyb- Doped Molybdenum ceramic insulators and finally short Molybdenum and tungsten materials denum plates of various thicknesses, Sagging behaviour of different molybdenum materials circuits, local melting, loss of energy are very successfully used in high typically 12.7 mm to 19.05 mm for a material and a drop in the maximum tempera- temperature MIM sintering furnaces. pusher continuous furnace. Ceramic In general, the high sintering ture. Similar effects can be observed These materials are of fundamental plates may also be used as pusher temperatures and contamination after contamination of the furnace importance for the performance plates. Compared to molybdenum from binder residuals lead to severe with oxygen or water due to incorrect of the furnace operation and the ceramic plates reduce the load capacity wear of the hot zone and the carrier operation or leakage (Fig. 1, left). economy of the process. Fig. 2 shows due to the required thickness, require support devices. MIM box and carrier The evaporation of residual binders furnace components typically made of slower heating and cooling rates to performance can be improved by inherent in the “green” parts may lead refractory metals. avoid breakage through thermal shock replacing the original OEM parts to the formation of hydrocarbon gases In continuous furnaces, serpentine and can result in lower temperature with more advanced materials such that could be retained in the sintering molybdenum and tungsten heating homogeneity of the sintered parts, due as ML molybdenum alloy. Enhanced hot zone furnace. Depending on the elements are used consisting of solid to high heat capacity of ceramic plates. metallurgical properties of high concentration of these gases and the rod or braided wire cable. The heating In batch furnaces the molybdenum performance materials allow for the efficiency to purge the furnace work elements are secured by molybdenum all-metal hot zone consists of the longer life of furnace components: area, the retained hydrocarbons may hooks or held in ceramic shoulders. shield pack, heating elements and result in carburisation of the hot zone In order to reduce the carburising hearth assembly. Some furnace • Less sagging of charging plates heating elements and the hot face effect from binder residuals, tungsten concepts use a MIM-box inside of and sintering boats shielding. As a consequence, heating rods may be preferred for some the hot zone in order to achieve a • Hearth components tend to elements and hot zone shielding applications. better control of the gas flow and remain straight and true Fig. 6 Sagging behaviour of different molybdenum materials (load for 1.5 hours at become brittle and deformation takes The loading assembly in continuous higher temperature uniformity during 1600°C in a high-vacuum furnace)

56 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 57

September 2010 front section new56 56 9/10/2010 12:43:46 PM September 2010 front section new57 57 9/10/2010 12:43:48 PM Higher efficiency MIM furnaces Global PIM Patents

• Reduction of the sheet thickness in the shield pack due to the development of a circumferential Global PIM Patents

spacer system • Replacing of stainless steel in the shield pack (efficiency of one The following abstracts of PIM-related patents have been derived molybdenum layer is equivalent to from the European Patent Organisation databases of patents from five stainless steel layers) • Usage of high-strength stainless throughout the world. Full information on individual patents (in the steel for support frame. language of the country) is available through the PIM International As an example, the benefits of editorial office converting a standard 24”x24”x36” all-metal hot zone into a low-mass hot Fig. 7 Original MIM furnace hot zone (left) and advanced re-designed hot zone (right) zone are: • Reduction of total hot zone weight by 15 % to 20% • Decreased heat loss by approxi- mately 15 kW (one molybdenum KR20080083693 (A) JP2008194718 (A) layer replaces two SS layers) POWDER INJECTION MOULDING REvERSE FLOW PREvENTIvE METHOD AND REvERSE FLOW • Lower energy demand for heating METHOD OF GLASS AND GLASS- PREvENTIvE DEvICE OF METAL INJECTION MOULDING up and cooling down per cycle by CERAMICS MACHINE 25 to 30 kWh Publication date: 2008-09-18 Publication date: 2008-08-28 • Quench performance is improved Inventor(s): E. Coonan et al, Corning Inventor(s): y. Kihara yuji, Japan Steel Works Ltd, Japan by a minimum of 15% Inc, USA A pushing metal (11) and a reverse flow preventive ring (15) are provided on • Faster ramp-up by 20% (empty A method for producing glass or glass a fore end of a screw (2). Piston ring grooves (18, 18) are formed in an out- furnace). ceramic articles by powder injection er circumferential part of the reverse flow preventive ring (15), and through moulding of glass powder includes In order to further decrease the holes (19) opened in a molten metal passage (10) inside a cylinder (1) are mixing together, in a continuous mixing energy consumption of an all-metal hot opened in the bottom of the grooves. Small diameter inner piston rings process, ingredients to form a mix- zone Plansee may also use composite (20, 20) and large ture comprising a glass powder and a shielding in which a thin layer of a diameter outer binder. The ingredients include a glass special alumina paper is added to piston rings (21, powder in a relative amount sufficient the low-mass shielding design. The 21) are attached to equal at least 50% by volume of the alumina paper quality and thickness is to the piston ring resulting mixture and a binder com- selected in such a way that the char- grooves (18, 18) prising a thermoplastic polymer. Form- acter of an all-metal hot zone, such as in a superposed Fig. 8 MIM hot zone utilising all-metal shielding, ML for heating element and U-shaped ing the mixture into a formed structure, high heating and cooling rates, short manner. The hearth rails de-binding and sintering the formed cycle times and carbon-free environ- injection pressure structure follow. The forming process and charge carrier were re-designed, an all-metal hot zone can be reduced ment, remain unaffected. The energy or the pressure may include pelletising the mixture fabricated and installed by Plansee by 20 to 25%, improving the perform- consumption is however reduced by keeping force is and injection moulding the pelletised (right image). The implementation ance at the same time. 10 to 15%. The paper consists of pure indirectly applied mixture to form the formed structure. of the new hot zone into the existing Lower mass in the hot zone equates alumina free from organic content. to the outer piston furnace took place without any changes to less material to heat up and cool In order to achieve such results rings (21). to the vessel or power supply. down for improved thermal efficiency without negative impact on the service US2008253916 (A1) and overall performance. As a result time, a deep understanding and METHODS OF MAKING STENTS CN101279851 (A) ture of polyethylene and polypropylene the furnace conditions (temperature, knowledge in terms of material proper- Enerzone: Innovation for Publication date: 2008-10-16 HEAT PLASTIC ADHESIvE SyS- as a skeleton material can ensure the atmosphere) can be changed faster, ties, fabrication capabilities and design Inventor(s): N. Istephanous et al, TEM SUITAbLE FOR ALUMINA adequate intensity of a base and have less energy consumption cycle time made shorter and thus the aspects are required. Unfortunately, Medtronic Inc, USA CERAMIC INJECTION MOULDING a better effect than the original single total energy consumption per cycle is in most cases the application of such The reduction of energy consumption Manufacturing methods are provided Publication date: 2008-10-08 polyolefin. A small amount of stearic reduced. advanced solutions does not reduce is not only a matter of environmental to build modulated medical devices Inventor(s): Jing ya; Zhifeng Liu; acid serves as a surface active agent, Measures to reduce the weight the unit price in the same manner responsibility, but of production cost and segments of the devices for Cailou Zhou, China or a lubricant, and has the bridging go hand-in-hand with technological due to the usage of high performance saving as well. The energy-saving applications in the field of intralu- The invention belongs to the field function between the adhesive and advances (Fig. 8): materials, but it clearly increases the concept of the Enerzone comprises minal intervention, reconstruction, of ceramic injection moulding, in powder particles for preventing the performance and reduces the opera- different aspects: • The usage of doped molybdenum or therapy. The methods, comprise particular to a thermoplastic adhesive two-phase separation and ensuring tional costs. • Reduced mass allows reduction of material thick- steps of metal injection moulding and fit for the aluminium oxide ceramic the evenness of the mixed material. • Improved shielding efficiency of an ness, e.g. for charging devices and processes of modulation, improve injection moulding and a method It can also play a role in the lubrica- all-metal hot zone hearth components such as rails Contact the manufacturability of the devices for the production. The adhesive is a tion between powder particles and • Composite shielding with ceramic and posts and/or expand the design alternatives thermoplastic adhesive with a paraffin between powder particles and a mould Plansee Metall GmbH fibre paper. • Improved design and fabrication for the devices. The modulated medi- wax/stearic acid/polyethylene/poly- wall. The aluminium oxide ceramic methods for hearth rails (U- A-6600 Reutte, Austria cal devices and their segments, made propylene mixed system. Wherein the product with high performance can be As a result of the above mentioned shaped rails), element supports Tel: +43 5672 600 2562 from the present method inventions, paraffin wax serves as a main filler made by injection moulding through measures the total energy consump- (one-piece bending) and power Email: [email protected] enhance the versatility in intraluminal because of low softening temperature optimising the formula of the adhe- tion for a typical MIM sintering cycle in feed-throughs www.plansee.com treatments. point and good fluidity. Taking a mix- sive.

58 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 59

September 2010 front section new58 58 9/10/2010 12:43:51 PM September 2010 back section new.59 59 9/10/2010 9:56:33 AM Technical Paper Technical Paper

mobile mould half slide block Titanium parts by powder injection angular pin slider

ejector plate fixed mould half moulding of TiH2-based feedstocks

insert E. Carreño-Morelli1, W. Krstev1, b. Romeira1, M. Rodriguez-Arbaizar1, H. Girard1, J.-E. bidaux1, S. Zachmann2

1Design & Materials Unit, University of Applied Sciences Western Switzerland, CH-1950 Sion 2Nabertherm GmbH, 28865 Lilienthal, Germany

Titanium parts have been processed from feedstocks composed of titanium hydride powders, low density polyethylene, paraffin wax and stearic acid. A two-step debinding process has been used, which consists of solvent debinding in heptane at 50°C followed by thermal debinding at 500°C. Sintering was performed at 1200°C. Both thermal debinding and sintering were performed under a protective atmosphere in a MIM Fig. 2 Mould half for tensile test specimen Fig. 3 Tool set (mould frame, inserts, slide) and drawing of watch bracelet segment furnace equipped with molybdenum heating elements and a debinding retort. Special care in powder handling, and dimensions of the mould cavity in mm feedstock preparation, debinding and sintering atmospheres, allowed to limit the residual oxygen, nitrogen The binder consisted of 55 wt% paraffin wax (Fluka Chemie (Fig. 5). A gas flow of 100 l/h is used for a continuous renewal of and carbon contents, which were determined by quantitative analysis. The mechanical properties of net-shape GmbH, Buchs, Switzerland), 35 wt% low density polyethylene the debinding atmosphere. sintered parts were measured by tensile tests. A tensile strength of 580 MPa and an elongation of 1.8% were (LDPE Riblene MP30, Polimeri Europa, Italy) and 10 wt% stearic Thermogravimetric analysis of TiH powders performed in obtained. Experimental watch bracelet segments were injection moulded, showing good shape preservation 2 acid (Fluka Chemie GmbH). The binder volume fraction was 40 a Setaram TAG 24 device allowed to establish that 500°C is and reproducibility. vol%. Feedstocks for powder injection moulding were prepared also an appropriate temperature for dehydrogenation. Hydrogen in a Coperion LUK 1.0 sigma blade mixer (Werner & Pfleiderer, removal proceeds during the subsequent heating to reach the Stuttgart, Germany). Mixing was performed at 140°C for 4h. Then, sintering temperature. At about 700°C, dehydrogenation is polymer-powder granules were obtained by cooling down and completed. Sintering was performed at 1200°C for 1h under crushing the mixture by slow shearing. flowing argon.

Injection moulding Material characterisation Tensile test specimens (Fig. 2) and experimental watch bracelet Density measurements were performed by using the Archimedes segments were injection moulded in an Arburg 221K 350-100 method. Mechanical properties were characterised by standard Introduction machine (Arburg GmbH + Co KG, Lossburg, Germany). tensile tests. Metallographic preparation of sintered samples was The excellent properties of titanium and titanium alloys have been The mould for watch bracelet segments (Fig. 3) consists of performed by diamond polishing followed by oxide polishing with extensively reported, as well as the complex processing steps, which single cavity inserts in a mould frame. A slide block with two colloidal silica. Quantitative analysis was performed by fusion are currently necessary for the production of engineering parts with pins is mounted on the mobile mould half. An angular pin slider in the fixed mould half forces motion of the slide block when the D 10 D 50 D 90 D [4,3] SSA these materials [1]. As a consequence, the interest of producers TiH v v v and end-part users on net-shape technologies is growing. Recently, mould closes. It allows transverse holes along the parting line to be 2 [µm] [µm] [µm] [µm] [m2/g] considerable progress in powder injection moulding of titanium and obtained for further assembly of the segments to each other. Mould TIH-25AA 4.72 9.43 17.01 10.18 0.21 its alloys has been accomplished [2-6]. This is due to the advances temperature was about 40°C. in production of good quality base-powders, binders and sintering TIH-020A 10.30 19.52 34.43 21.10 0.09 facilities. However, cost of raw materials, especially for gas atomised Debinding and sintering powders, is still a limiting factor for a number of applications. In this After shaping, the parts were subjected to successive treatments Table 1 Particle size parameters and specific surface area of fine and work, net-shape manufacturing of titanium parts has been performed of solvent debinding, thermal debinding, dehydrogenation and coarse TiH2 powders by powder injection moulding from titanium hydride powders, sintering. which have the attractiveness of being less reactive than fine titanium Solvent debinding was performed in heptane at 50°C for 10 h, powders, easier to handle, and cheaper [7-8]. which allowed the removal of more than 98% of paraffin wax and stearic acid. Experimental Thermal debinding, dehydrogenation and sintering steps were accomplished in a single thermal cycle in a Nabertherm VHT8- Raw materials and feedstock processing 16MO MIM furnace, which is equipped with molybdenum heating Two types of TiH powders from AG Materials Inc., Taiwan, 2 elements and a debinding retort (Fig. 4). The furnace design allows were used: a fine TIH-25AA grade (D 50 = 9.43 µm) and a coarse v safe evacuation of products resulting from binder burnout without TIH-020A grade (D 50 = 19.52 µm). The angular morphology of v contaminating the heating elements. During debinding, a gas flow these powders can be seen in Fig.1. The scanning electron microscopy is currently activated into the furnace chamber, and gas aspiration observations were performed in a LEO1525 microscope. is directly made from the retort. During sintering, the gas flow is The particle size distribution was determined by laser activated into the retort, and aspiration is made from the furnace diffractometry in a Malvern Mastersizer 2000 apparatus. Table 1 chamber. A binder trap, which is periodically cleaned, avoids a) b) presents the particle size parameters D 10, D 50 and D 90 as well v v v contamination of the vacuum pump. Thermal cycles can be done as the volume moment mean diameter D [4,3]. The specific surface under vacuum or controlled atmosphere of Ar, N2 or H2. Fig. 4 Fig. 4 Details of the debinding and sintering furnace: (a) heating area is estimated as SSA=6/(ρ.D[3,2]), where D [3,2] is the surface shows details of the furnace chamber and retort. elements and debinding retort closed, (b) sintered watch bracelet area moment mean diameter and ρ = 3.9 g/cm3 is the density of Fig. 1 Scanning electron microscopy of starting TiH powders: 2 Thermal decomposition of the LDPE backbone polymer was segments on zirconia coated alumina support, placed on molybdenum TiH . fine TIH‑25AA (top) and coarse TIH‑020A (bottom) 2 accomplished during a debinding step of 1 h at 500°C under argon plates inside the retort

60 Powder Injection Moulding International September 2010 Vol. 4 No. 3 Vol. 4 No. 3 September 2010 Powder Injection Moulding International 61

September 2010 back section new.60 60 9/10/2010 9:56:35 AM September 2010 back section new.61 61 9/10/2010 9:56:38 AM Technical Paper Technical Paper

Fig. 5 Thermal cycle for processing Ti parts from solvent debinded TiH2 based feedstocks Fig. 7 Tensile stress‑strain curve of sintered PIM‑Ti (coarse powder)

and infrared detection with a LECO TC500 system to establish the content of interstitial elements O, N, C in base powders and sintered parts. Fig. 8 Optical metallography showing the microstructure of sintered Fig. 9 Titanium watch bracelet segments processed from TiH2 based PIM‑Ti (fine powder) feedstock Results and discussion Fig. 6 shows green parts (as injected) and net-shape parts (after elongation to fracture is much less than the one of titanium grade 4. debinding and sintering). Good green strength is due to low density Further improvement in ductility would be possible by optimising polyethylene, which is the backbone polymer of the multicomponent the debinding, dehydrogenation and sintering cycle (e.g. by

binder. The goal of the solvent debinding step is to remove paraffin increasing sintering temperature and time), and by using TiH2 wax and stearic acid, leaving an open porosity to allow proper powders of higher purity. thermal debinding of the backbone polymer. In this way, gas bubble The microstructure of sintered parts is shown in Fig. 8. An formation during polymer burnout is avoided, reducing internal equiaxed grain structure is found, with reduced grain size near the stresses and the risk of part damage or geometry distortion. surfaces. Residual round porosity is also observed.

The linear shrinkage of sintered titanium parts is about 19%. This At the present state of research, injection moulding of TiH2 high value is because, in addition to the current contraction during feedstocks appears as an interesting alternative for manufacturing debinding, there is also a contraction during the dehydrogenation of lightweight strong parts, when ductility is not the critical

of the TiH2 base powder. requirement. PIM titanium parts from fine TIH-25AA powders have a density Sintered watch bracelet segments show good shape preservation higher than 98% of the theoretical density and tensile strength and reproducibility. The variation in weight of green parts is Fig. 10 Watch bracelet segments after successive surface treatments: of 650 MPa, but low ductility (Table 2). This is related with the less than 0.4%. The linear shrinkage is about 20%, and the hole barrel finishing (dark grey), etching and electropolishing (light grey), too high oxygen content, about 60 wt.%, which was measured by diameter ø is reduced from 0.98 mm to 0.78 mm after sintering. and anodic oxidation (blue, yellow) fusion and infrared detection. A control of weight and dimensions was performed on 63 sintered Better results are obtained with PIM titanium parts from coarse parts. The variation in weight is again less than 0.4%. The scatter in References TIH-020A powders. This is related with a lower interstitial content, dimensions a and b is about 0.4 %, and the scatter in the dimension especially oxygen, compared with fine powders (Table 2). Coarse c is about 0.5% (Fig. 3 and 9). [1] M. J. Donachie, “Titanium, a technical guide”, 2nd Edition, powders have a lower specific surface area, which results in lower The parts can be surface treated by barrel finishing, etching, ASM International, Materials Park, Ohio, 2000 reactivity and reduced contamination during production, handling electropolishing and anodic oxidation (Fig. 10). [2] Y. Itoh, T. Harikou, K. Sato, H. Miura, Proc. of PM2004 Powder and further shaping and consolidation treatments. Sintered density Metallurgy World Congress, Vienna, Austria, 17-21 October 2004, pp. 445-450 is lower, but ultimate tensile strength of 580 MPa meets the Concluding remarks requirements for Ti grade 4. In addition, elongation to fracture [3] F. H. Froes, Metal Powder Report, 61, 11, 2006, pp. 20-23 Titanium hydride powders are an interesting alternative for Fig. 6 Green and sintered PIM‑Ti parts is improved to reach 1.8 % plastic strain (Fig. 7). However, the [4] T. Ebel, PIM International, 2, 2, 2008, pp. 21-30 processing PIM-Ti parts. Despite its angular shape (which is [5] R. Zhang, J. Kruzewski, J. Lo, PIM International, 2, 2, 2008, currently associated with low packing and high interparticle pp. 74-78 O N C sintered elongation friction) and a necessary dehydrogenation step, sintered densities [6] R. M. German, PIM International, 3, 4, 2010, pp. 21-37 Dv50 [µm] UTS [MPa] [wt.%] [wt.%] [wt.%] density [%] [%] higher than 95% can be obtained. Net-shape as-sintered parts [7] E. Nyberg, M. Miller, K. Simmons, K. Scott Weil, Mat. Sc. Eng. show good mechanical properties, good shape preservation and C 25 (2005) pp. 336-342 TIH-25AA powder 9.80 0.25 0.24 0.16 - - - reproducibility. Further improvements in ductility will be related [8] Y. Li, X.M. Chou, L. Yu, Powder Metallurgy, 49, 3, 2006, pp. with the optimisation of debinding, dehydrogenation and sintering 236-239 PIM-Ti (a) - 0.60 0.013 0.10 98.2 650 0.7 cycles, and with the availability of powders of improved purity.

TIH-020A powder 19.55 0.07 0.14 0.013 - - - Acknowledgments PIM-Ti (b) - 0.38 0.046 0.045 95.8 580 1.8 The authors would like to thank A. Moreillon and G. Follonier for their help in mould design. The technical support of A. Steiner, D. Ti grade 4 - 0.4 0.03 0.08 550 15 Zufferey, H. Hamdan (HES-SO Valais) and J. Dänzer (BFH-Biel) is gratefully acknowledged. Table 2 Interstitial content and mechanical properties of base powders, titanium standard grade 4, and PIM‑Ti processed from fine (a) and coarse

(b) TiH2 powders

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Characteristics PIM Pressing Casting Machining Extruder Specifications values Properties of SiC and AlN feedstocks for Density 90-100% 95-100% 95-99% 100% Screw Diameter (Co-Rotating) 27 mm Surface Finish 0.4 to 0.8µm < 2µm 3µm 0.4 to 2µm L/D 40 the powder injection moulding of thermal Secondary Not Flight Depth 4.3 Required Required - Machining required Barrels/Zones involved 10 management devices Wall Thickness 10 µm >2mm >5mm >2mm Zone Temperatures 160 °C Dimensional Close Poor Poor Poor Screw Speed 260 rpm 1 1 2 3 1 Tolerance valmikanathan P. Onbattuvelli , Srikar vallury , Timothy McCabe , Seong Jin Park and Sundar v. Atre Extrusion Rate 30 lb/hr 1 Oregon Nanoscience and Microtechnologies Institute, Oregon State University, OR 97331, USA Shape Complexity High Medium Medium High Air-cooled conveyor Cooling System [email protected] Production Rate High High Low Low belt system 2Kinetics Inc., Wilsonville, OR, USA 3Pohang University of Science & Technology, Republic of Korea Table 2 Comparison of the net‑shaping processes for SiC and AlN Table 3 Twin screw extrusion conditions used for compounding SiC and AlN feedstocks Aluminium nitride (AlN) and silicon carbide (SiC) were chosen for the fabrication of thermal management devices Feedstock Formulation and Scale-Up spectrometer (EDAX). A Gnomix PVT apparatus was used to find due to their high thermal conductivity and coefficient of thermal expansion values equivalent to that of silicon and As mentioned in the introduction section, our prior findings the PVT relationships of the feedstock materials. The PVT tests silicon carbide dies. Additionally, powder injection moulding (PIM) was selected for net-shaping these ceramics involve an increased critical solids loading (φm) of 70 and 65 were carried out in accordance with ASTM D 792. The pellets in order to harness its production and geometric advantages. This paper presents an in-depth study on the effect vol.% for the bimodal μ-n SiC and AlN powder mixtures [29-30]. were dried for 4 hours at 70°C under vacuum. The measurement of nanoparticles addition on the thermal and rheological properties of the SiC and AlN feedstocks. Specifically, To facilitate a consistent part fabrication via the PIM process a type used was an isothermal heating scan with a heating rate of bimodal mixtures of nanoscale and sub-microscale particles addition were found to significantly improve the powder homogeneous feedstock (~2-5 vol.% < φm) was designed. Thus, approximately 3°C/minute. Mouldflow software was used for content (solids loading) in the powder-polymer mixtures (feedstocks) for injection moulding. The implications of formulations with optimal solids loading (φ) of 64 and 60 vol.% simulating the injection behaviour using the measured properties. the variation in feedstock properties with nanoparticle additions are discussed in the context of the mould filling for SiC and AlN respectively, were compounded using twin screw behaviour of these material systems. extrusion. The conditions used for the scale-up are listed in the Keywords: SiC, AlN, powder injection moulding, thermal management, nanoparticles Table 3. Similarly, feedstocks of monomodal μ -sized SiC and Results and Discussions AlN powders with φ of 52 and 51 vol.% respectively, were also Thermal Properties compounded for comparison purposes. The thermal properties of the extruded feedstocks provide basic guidelines for the subsequent PIM steps. Figs 1(a) and 1(b) show Instrumentation the DSC curves of all the feedstocks where two endothermic Introduction Thermogravimetric analysis (TGA) was performed on the extruded peaks at 62± 2°C and 130±3°C are observed during heating. These Silicon carbide (SiC) and aluminium nitride (AlN) exhibit a μ–n powder mixture [29-30]. For example, the critical solids loading feedstocks using a TA- Q500 (TA instruments) thermal system peaks indicate the melting of filler phase (paraffin wax) at 62°C combination of thermal and mechanical properties (Table 1) that is found to increase from 54 to 70 vol.% when AlN nanoparticles operated under nitrogen flow in the temperature range of 50-600°C and backbone polymers (polypropylene) at 130°C. Similar results are relevant to applications in electronics, aerospace, defence and are added to the monomodal μ–sized AlN powders. Similarly, the with a heating rate of 20°C/min. The calorimetric measurements were observed by Aggarwal et al for niobium injection moulding automotive industries [1-4]. However, the successful translation of SiC powder mixture exhibited an increase from 53 to 65 vol.% were carried out using a TA- Q1000 unit (TA instruments) over a [33] and Liu et al for stainless steel injection moulding [34]. With these properties into final applications lies in the net-shaping of with the nanoparticles addition. With these new formulations temperature range of 20-200°C. The samples were heated at the the composition of the binder being constant, minor/no shifts are these ceramics into fully dense microstructures. Extensive research developed, the focus now shifts onto the feedstock characterisation rate of 20°C/min under a nitrogen atmosphere. The rheological noticed in the melt peaks with the nanoparticle addition. However, has been done on net-shaping SiC and AlN via slip casting [5-6], for the successful completion of the PIM process. The current work characteristics of the feedstock were examined on a Gottfert an increase in the heat flow is well pronounced in both SiC and AlN tape casting [7-8], hot pressing [9-10], hot isostatic pressing [11-12] provides a comparative study on the properties of the monomodal Rheograph 2003 capillary rheometer at different shear rates and bimodal feedstocks. The corresponding reduction in the specific and cold isostatic pressing [13-14]. Additional methods including and bimodal SiC and AlN feedstocks. The primary objective is thus temperatures. The rheology tests were carried out in accordance heat values could be explained as the possible outcome of increased pyrolysis of pre-ceramic polymers were also explored but are in to study the effect of nanoparticles on the thermal, rheological and with ASTM D 3835. The temperatures were between the highest powder content with the nanoparticle addition. their infant stages at the present time [15-16]. Unfortunately, PVT properties of the bimodal feedstocks. Additionally, effort is melting temperature and the lowest degradation temperature of the From the TGA plots (Figs. 2a and 2b), the powder content in the little research involving powder injection moulding (PIM) of SiC taken to carry out simulation studies on the mould filling behaviour. binder system. A barrel of inner diameter 1 mm and a die length of SiC and AlN monomodal feedstocks can be finalised 79.5±0.2 wt.% and AlN has been reported to date [17-19]. It is evident from a 20 mm was used. The preheating time was kept at 6 minutes. The and 80.5±0.2 wt.%, respectively. The advantage of nanoparticle comparative study presented in the Table 2 that PIM has many Experimental Methods micrographs of the thermally debound feedstock samples were addition is once again confirmed from the plots of bimodal SiC and advantages over competing net-shaping techniques to mass taken with a QuantaTM –FEG (FEI) dual beam scanning electron AlN feedstocks revealing the powder content as 82±0.4 wt.% and Materials produce complex geometric parts for thermal management with microscope (SEM) coupled with an energy dispersive X-ray 85±0.2 wt.%, respectively. The two stage degradation exhibited by Commercially available α-SiC, AlN, and Y O were used as the closer dimensional tolerances. 2 3 Irrespective of the fabrication techniques, dependant on the starting materials as received. Similar to the earlier reports on thermal and mechanical properties, the densities of the fabricated PIM, a multicomponent polymer system based on paraffin wax, ceramics are aimed towards their theoretical limits [20-21]. Prior polypropylene, was chosen as the binder to facilitate a multi-step reports investigated this issue by exploring the material and debinding process [31-32]. process parameters. For example, immense effort was taken in the Property SiC AlN past to understand the effect of nature and content of the sintering additives on the densification of SiC and AlN [22-23]. Similarly, Density (g/cc) 3.2 3.26 process parameters including sintering temperature, hold time and Thermal Conductivity (W/m.K) 120 170 pressure were varied to study the pattern of densification and/or CTE (10-6/°C) 4 4.5 grain growth [24-26]. Improving the green density of the feedstock provides an Vicker’s Hardness (GPa) 22 10.4 important parameter to increase the final density during sintering. Fracture Toughness (MPa.m0.5) 4.5 2.6 (a) (b) This can typically be achieved by increasing the solids loading of Flexural Strength (MPa) 450 320 the feedstock by blending two different particle sizes [27-28]. Our ^4 ^14 prior research work successfully demonstrated an increase in the Volume Resistivity (Ω.cm) 10 >10 solids loading with the addition of nanoparticles, forming a bimodal Table 1 Properties of sintered SiC and AlN ceramics Fig. 1 DSC curves confirming the melt peaks of the monomodal and bimodal SiC (a) and AlN(b) feedstocks along with their specific heat.

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Effort is also taken to evaluate the role of nanoparticles addition on the pseudoplastic behaviour by fitting the rheological data into a modified Cross-WLF equation:

(a) (b) ...... …. (1) Fig. 5 Comparison of powder packing behaviour in monomodal (a) and bimodal (b) SiC feedstocks where, and

with D3= 0 (in this paper) ( )

η0 is the zero-shear rate viscosity, γ is the shear rate, T is the

Fig. 2 TGA confirming the composition of the monomodal and bimodal SiC (a) and AlN (b) feedstocks along with their thermal profiles. temperature, P is the pressure, n , τ* , D1, D2, D3, A1 and A2 are model constants. Along with their definitions, the values of these all the feedstocks correspond to the degradation of the filler phase carbon during the thermal debinding stage. In addition to the above parameters are listed in the Table 4. from 175-400°C and backbone polymers from 400-550°C. This discussion, the DSC and TGA results can also be utilised to set a Most of the PIM feedstocks demonstrate two patterns of fluidity: pyrolysis data can be used for establishing the upper limit for the lower and upper limit for the injection moulding temperatures. In Newtonian and shear thinning. While Newtonian behaviour exhibits injection moulding temperatures and thermal debinding profiles our present work, the injection temperature for all feedstocks can a linear shear stress - shear rate relationship, the latter involves [28]. Figs 2a and 2b also reveal a shift in the degradation peaks for be ranged between 135°C and 180°C. more fluidity at higher shear rates [36]. The onset of such transition the SiC and AlN bimodal feedstocks. This expedited degradation in the feedstock’s fluidity pattern is represented by a shear stress might be due to the presence of additional nanoparticles whose Rheological Properties (a) (b) parameter, τ*, in the above equation. The slope of the shear-thinning inclusion is found to increase the heat flow in the feedstocks. To evaluate the dependence of feedstock viscosity on temperature, Fig.6 Comparison of powder packing behaviour in monomodal (a) and curves in Figs. 3 and 4 is represented by the value (1-n) where n

Contribution to such behaviour might also be extended to the the apparent viscosity (η) - shear rate (γ) curves of the extruded bimodal (b) AlN feedstocks is the power law coefficient. From the (1-n) and D1 values, given higher surface area of the nanoparticles. This finding in bimodal SiC and AlN feedstocks were measured at different temperatures, in Table 4, it is evident that the nanoparticle addition increases the mixtures rejects the expected delay in the binder removal due to as shown in the Figs 3 and 4, respectively. The temperatures were of the content, the viscosity of all the feedstocks decreased with shear-thinning behaviour of the feedstock. However, the increased reduced porosity. However, further research is required in studying between the highest melting temperature (135°C) and lowest an increase in shear rate, indicating pseudoplastic behaviour. The τ* values for the bimodal feedstocks suggest that an additional the effect of nanoparticle addition on the percentage of residual degradation temperature (180°C) of the feedstocks. Irrespective result once again confirms the absence of dilatant behaviour, shear stress is required to begin the shear-thinning regime. Further indicating no powder-binder separation. Normally, feedstock comparative studies on the feedstocks containing equal powder exhibiting pseudoplastic flow during moulding eases mould filling content might give an in-depth understanding about the effect of and minimises jetting [35]. Additionally, the viscosity of all the nanoparticles on the shear–thinning behaviour. Additionally, the feedstocks tends to decrease with increasing temperature. This higher coefficient values of monomodal SiC feedstock compared might be attributed to powder volume reduction arising from larger to that of AlN feedstock necessitates future studies on the effect binder expansion and disentanglement of the molecular chain that particle shape has on the flow behaviour. during heating [33]. The viscosity of both SiC (Fig. 3b) and AlN bimodal feedstocks PVT Measurements (Fig. 4b) were found to be higher that of the monomodal feedstocks The pressure - volume - temperature (PVT) behaviour of the SiC (Figs. 3a and 4a) at any given shear rate - temperature conditions. (Fig. 7) and AlN feedstocks (Fig. 8), gives the specific volume This may be due to the increased powder content in the feedstocks of the melt in the cavity as a function of the cavity pressure and with the nanoparticle addition. As shown in the SEM micrographs temperature. These plots help in understand the compressibility and (Figs. 5b and 6b), in the bimodal feedstocks, the nanoparticles temperature effects during a typical injection moulding cycle. The fit into the interstitial spaces between the microparticles without hold pressure should be chosen after appropriately referring to the (a) (b) forcing them apart. Nanoparticle inclusion will also greatly increase PVT diagram so that the residual cavity pressure is near atmospheric the overall interfacial area between the powder and binder phases. pressure before mould opening [36]. This in turn ensures avoidance Fig. 3 Viscosity of the extruded monomodal (a) and bimodal (b) SiC feedstocks at different shear rate and temperature combinations, confirming The extent to which the increased hydrodynamic resistance affects of any part ejection and/or relaxation issue. From the Figs. 7 and its pseudo‑plastic behaviour the feedstock fluidity will be examined in a separate study. 8, it is clear that the monomodal feedstocks have higher slope

SiC Feedstocks AlN Feedstocks Coefficients Definitions Monomodal bimodal Monomodal bimodal (1-n) slope of the shear-thinning curve 0.84 0.93 0.63 0.95

Constant with Weissenberg-Rabinowitsch τ* (KPa) 28 127 12 178 correction at user’s specification during data fit

D1 (Pa-s) Scale factor for viscosity 0.17E+19 10 E+19 8.77E+10 9.13 E+19

A1 WLF temperature shift factor 37.73 42.69 14.24 29.54 Glass transition temperature at zero gauge D (K) 263 2 pressure A (K) WLF temperature shift factor 51.6 (a) (b) 2 Table 4 Values of different rheological constants for SiC and AlN feedstocks Fig. 4 Viscosity of the extruded monomodal (a) and bimodal (b) AlN feedstocks at different shear rate and temperature combinations, confirming its pseudo‑plastic behaviour

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SiC Feedstocks AlN Feedstocks Coefficients Definition Monomodal bimodal Monomodal bimodal b5 (K) Crystallization temperature 7.1E+01 6.9E+01 5.8E+01 6.3E+01 b6 (K/Pa) Pressure sensitivity of b5 1.05E-01 1.6E-01 1.65E-01 1.45E-01 b1m (m3/kg) 5.15E-01 4.75E-01 4.83E-01 4.46E-01 b2m (m3/kg-K) 3.09E-04 2.33E-04 3E-4 1.86E-04 Tait constants for melt b3m (Pa) 2.83E+02 3.19E+02 2.87E+02 3.43E+02 b4m (1/K) 5.23E-03 4.84E-03 4.82E-03 4.03E-03 b1s (m3/kg) 5.03E-01 4.63E-01 4.69E-01 4.37E-01 b2s (m3/kg-K) 1.9E-04 1.53E-04 9.7E-05 1.49E-04 Tait constants for solid (a) (b) b3s (Pa) 3.72E+02 5E+02 5.79E+02 5E+02 b4s (1/K) 6.73E-03 1E-02 1.26E-03 1E-02 Fig. 7 PVT relationships for monomodal (a) and bimodal (b) SiC feedstocks b7 (m3/kg) 1.23E-02 1.22E-02 1.49E-02 0.9E-02 Transition of specific volume b8 (1/K) 6.16E-02 9.03E-02 1.1E-01 1.31E-01 from solid to melt b9 (1/Pa) 8.5E-03 1.59E-02 2.12E-02 2.22E-02

Table 5 PVT coefficients for SiC and AlN feedstocks Injection Moulding Simulations Figs. 9a-d depict the progressive filling pattern during injection moulding of the monomodal SiC feedstocks. Similar patterns were noticed for other feedstocks as well. Simulations were performed to evaluate the effect of melt temperature on the mould fill time. From Fig. 10, it can be seen that the fill time decreases with an increase in the melt temperature, as expected with the shear thinning behavior of the feedstocks. Irrespective of the melt temperatures, the bimodal feedstocks showed prolonged fill time compared to that of the (a) (b) monomodal feedstocks. This might be inferred as the outcome of increased bimodal feedstock viscosity due to nanoparticle addition, Fig. 8 PVT relationships for monomodal (a) and bimodal (b) AlN feedstocks as discussed in the previous sections. Fig. 10 Fill time vs injection temperature for all feedstocks, revealing Additional simulations were performed to further understand that the nanoparticle addition slows the mould filling process values implying more thermal expansion than those of the bimodal However, the specific volume at transition temperature is the effect of feedstock viscosity on the mould filling behaviour. feedstocks. Thus, the increased powder content via nanoparticles considered to be zero while heating the feedstock. It is represented Thus, an average melt velocity is calculated and plotted against the addition reduces the thermal expansion of the feedstock indicating with Equation 5. melt temperatures (Fig. 11). The lower melt velocity values once a lower tendency for shrinkage in the final part which is inversely ...... …...... (5) again confirm the reduced fluidity of the bimodal feedstocks due to proportional to packing density. The reduced specific volume once nanoparticles addition. These reduced velocity values can be directly again confirms the positive impact that the nanoparticle addition The specific volume at temperatures lower than the transition correlated to the increased mould filling time. Such prolongation in the has on the feedstock density. temperature is given by Equation 6, where the feedstock is a solid mould filling generally leads to heat transfer through the mould wall, Additional analysis is done by fitting the PVT data into a modified and semi-solid state. resulting in the formation of a thick frozen layer narrowing the actual Tait two-domain empirical model that defines two domains below …...... (6) flow channel [34, 38]. This in turn results in the increased shear stress and above a transition temperature Tf: at the walls for the bimodal feedstocks as plotted in the Fig. 12. In addition to the above discussions, it is necessary to understand Here, B (T) can be expressed as shown in Equation 7. the differences in the simulated values of monomodal SiC and AlN ...... (2) …...... ….. (7) Fig. 11 Melt velocity vs injection temperature for all feedstocks indicating the nanoparticle addition slows down the melt’s fluidity Where υ is the specific volume (cc/g), T is the temperature Here, is any specific temperature below the transition thereby increasing the mould fill time. (°C), P is the pressure (MPa), B(T) is a temperature dependent temperature. The specific volume while cooling, is given as shown

parameter with the same dimension as pressure, υ0 and υf are in Equation 8. the specific volumes at room temperature and at temperatures ...... (8) above the transition temperature respectively. Specific volume at temperatures higher than the transition temperature is given by The subscripts, m and s refer to the melt and solid states. Table 5 Equation 3. gives the values and definition of different PVT coefficients for the SiC and AlN feedstocks...... … (3) From Table 5, it is evident that nanoparticle addition brings in none or minor changes in the crystallisation temperature and the where and specific volume transition. This might be due to the fact that the where is any specific temperature above the transition binder composition is kept constant for both the monomodal and temperature. B(T) can be expressed as shown in Equation 4. bimodal feedstocks. Thus, similar to prior work by Wu et al on Fig. 9 Progressive filling pattern during the injection moulding of alumina (Al2O3) feedstocks, a future PVT analysis with varied monomodal SiC feedstock at 170°C, (a) 25% fill, (b) 50% fill, (c): 75% Fig. 12 Shear stress at the wall vs injection temperature for all feedstocks, ...... … (4) binder composition is required [37]. fill and (d) 100% fill indicating that nanoparticle addition increases the shear stress on the walls

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[3] A. Okada, Journal of the European Ceramic Society, vol. 28, 2008, and stay up-to-date with Pages: 1097-1104. [4] A. F. Junior, D. Shanafield, Journal of Materials Science: Materials in Electronics, vol. 16, 2005, Pages: 139-144. PIM industry developments [5] T. Yoshioka, Y. Makino, S. Miyake, H. Mori, Journal of Alloys and Compounds, vol. 408-412, 2006, Pages: 563-567. [6] T.S. Suzuki, Y. Sakka, Scripta Materialia, vol. 52, 2005, Pages: 583- 586. [7] X. Luo, J. Li, B. Zhang, W. Li, H. Zhuang, Journal of American Ceramic Society, vol.89, 2006, Pages: 836-841. To subscribe to Powder Injection Moulding International today please return this form by fax to: +44 [8] Y. Wu, Y. Liu, H. Zhou, Materials Chemistry and Physics, vol.56, 1998, (0)1743 469909 or subscribe on-line at www.pim-international.com Pages: 271-274. [9] S. Surnev, D. Lepkova, A. Yoleva, Materials Science and Engineering B, vol. 10, 1991, Pages: 35-40. [10] S. Du, Z. Liu, L. Li, Z. Gui, Materials Letters, vol. 25, 1995, Pages: Subscription to Powder Injection Moulding International for one year (4 issues) = £95 105-109. [11] X. L. Li, H.A. Ma, Y. J. Zheng, Y. Liu, G.H. Zuo, W.Q. Liu, J. G. Li, X. Subscription for one year + all back issues (since March 2007) *special offer* = £350 Jia, Journal of Alloys &Compounds, vol. 463, 2008, Pages: 412-416. [12] J. K. Lee, H. Tanaka, H. Kim, D. J. Kim, Materials Letters, vol. 29, 1996, Pages: 135-142. Your contact details Fig. 13 Multi‑slotted parts injection moulded with the monomodal SiC [13] M. Medraj, Y. Baik, W. T. Thompson, R.A.L. Drew, Journal of Materials feedstock Processing Technology, vol. 161, 2005, Pages: 415–422. Title...... Forename(s)...... Family.Name...... feedstocks in spite of their similar powder content. The orientation of [14] M. Fukushima, Y. Zhou, Y. Yoshizawa, Journal of Membrane Science, irregularly shaped micro-sized SiC particles along the cavity walls vol. 339, 2009, Pages: 78-84. Job.Title/Position...... [15] H. Hassanin, K. Jiang, Advanced Engineering Materials, vol. 11, 2009, could be suggested as the reason for its lower melt velocity and higher Pages: 101-105. Organisation...... shear stress values compared to that of monomodal AlN feedstock. [16] Y.C. Song, Y. Zhao, C.X. Feng, Y. Lu, Journal of Materials Science, vol. Similar orientation issues were explained in the past by Krug et al 29, 2002, Pages. 5745-5756. Full.address...... [38] and Gietzelt et al [39] in the injection moulding of irregularly [17] K.H. Lin, Y. C. Lin, S. T. Lin, Journal of Materials Processing shaped Al O particles. Based on the above discussion, a series of Technology, vol. 201, 2008, Pages: 701-705...... 2 3 [18] D. Xueli, M. Qin, H. Islam, P. Feng, X. Qu, Key Engineering Materials, injection moulding cycles were performed with the feedstocks to vol. 336-338, 2007, Pages: 1028-1030. Postcode...... Country...... mould a multi-slotted part as shown in the Fig.13. Our on-going work [19] X. Qu, D. Huang, M. Qin, D. Li, J. Lin, Rare Metal Materials and focuses on a detailed analysis of process simulations and moulding Engineering, vol. 30, 2001, Pages: 212-215. Tel:...... Fax:...... experiments to further understand the effects of nanoparticle additions [20] Y. Inomata, “Free energy theory of material transport for sintering and diffusional creep”, Proceeding of International Symposium on Ceramic E-mail:...... on mould filling behaviour of these feedstocks. Components for Engine, ed. S. Somiay et al, KTK Scientific Publishers, Tokyo, 1984, Pages: 253-261. Conclusions [21] Y. Uemura, Y. Inomata, Z. Inoue, Journal of Materials Science, vol. 95, 1981, Pages: 2333-2335. Subscription period This research emphasises the effect that nanoparticle addition has on [22] J. H. She, K.Ueno, Materials Research Bulletin, vol. 34, 1999, Pages: Powder Injection Moulding International is.published.on.a.quarterly.basis..Your.subscription.will.commence.with.the.next. the thermal and rheological properties of SiC and AlN feedstocks. 1629–1636. [23] D. Sciti, A. Bellosi, Journal of Materials Science, vol.35, 2000, Pages: available.issue.unless.otherwise.requested.([email protected]) It was observed that the nanoparticle addition expedited the binder 3849-3855. degradation by increasing the heat flow. Rheological measurements [24] M. C. Rodriguez, A. Munoz, A.D. Rodriguez, Journal of the European concluded a reduced fluidity for the bimodal feedstocks due to their Ceramic Society, vol. 26, 2006, Pages: 2397–2405. Multiple subscription discount *save 25%* increased powder content via nanoparticle addition. Coefficient [25] V. A. Izhevskyi, A.H.A. Bressiani, J.C. Bressiani, Journal of American Ceramic Society, vol.88, 2005, Pages: 1115-1121. Organisations.wishing.to.purchase.four.or.more.subscriptions.to.Powder Injection Moulding International can.receive. values obtained from the viscosity models indicated that additional [26] M. Bothara,S. V. Atre, S-J. Park, R.M. German, T.S. Sudarshan, R. 25%.discount.on.the.total.cost..Please.contact.Paul.Whittaker,.email:[email protected],.to.order. shear stress is required to initiate the pseudo-plastic behaviour in Radhakrishnan, NSTI Nanotech 2007, vol.4, 2007, Pages: 494-497. the bimodal µ-n feedstocks. Even though the nanoparticles addition [27] J. Y. Qiu, Y. Hotta, K. Watari, K. Mitsuishi, Journal of American was found to hold positive impact on the feedstock properties, the Ceramic Society, vol.89, 2006, Pages: 377-380. Payment options simulation studies concluded otherwise. The higher viscosity of the [28] P. Suri, S. Atre, R. German, J. D’Souza, Materials Science and Engineering A, vol.356, 2003, Pages: 337-344...... Please.invoice.me..I.understand.that.subscriptions.will.not.start.until.full.payment.is.made. bimodal feedstocks led to slower melt velocity which in turn increased [29] V. Onbattuvelli, G. Purdy, G. Kim, S. Laddha, S. Atre, Advances in the fill time and shear stress along the mould walls. Further studies Powder Metallurgy and Particulate Materials, no.1, 2010, Pages: 64-72...... Please.charge.£...... to.my.credit.card.as.follows:...... VISA...... MasterCard...... American.Express.... are on-going to determine whether additional benefits can be gained [30] V. Onbattuvelli, G. Purdy, G. Kim, S. Laddha, S. Atre, NSTI Nanotech during the sintering stage from using the bimodal µ-n feedstocks. 2010, vol.1, 2010, Pages: 800-803. [31] S. J. Park, Y. Wu, D.F. Heaney, X. Zou, G. Gai and R.M. German, Metallurgical and Materials Transactions A, vol. 40 A, 2009, Pages: 215-222. Name.on.Card:...... Acknowledgment [32] Y. Ahn, S.T. Chung, S.V.Atre, S.J. Park, R.M. German Powder Metallurgy, vol.51, 2008, Pages: 318-326. Card.Number:...... 3/4.Digit.Security.Code...... The authors thank S. Ramamoorthi (Oregon Nanoscience and [33] L. Liu, N.H. Loh, B.Y. Tay, S.B. Tor, Y. Murakoshi, R. Maeda, Materials Microtechnologies Institute), Dr. T. S. Sudarshan (Materials Characterisation, vol. 54, 2005, Pages: 230-238. Expiry.Date:...... Modification Inc.,) and S. G. Laddha (Pacific Northwest [34] G. Aggarwal, S.J. Park, I. Smid, International Journal of Refractory Metals & Hard Materials, vol.24, 2006, Pages: 253–262. . National Laboratory) for their technical support. The studies [35] R. S. Lib, B.R. Patterson, H.A. Heflin, Progress in Powder Metallurgy, were supported by funds provided by the Oregon Nanoscience vol. 42, 1986, Pages: 95-104. Signature:...... Date:...... and Microtechnologies Institute and a fellowship from Materials [36] S. G. Laddha, C. Wu, S-J Park, S. Lee, S. Ahn, R. M. German, S.V.Atre, Modification Inc. International Journal of Powder Metallurgy, vol.46, 2010, Pages: 49-58. [37] C. Wu, S.V. Atre, S. Laddha, S. Lee, K. Simmons, S-J. Park, R. German, PIM International, vol. 2, 2008, Pages: 68-73. Or mail to: Inovar Communications Limited, 2 The Rural Enterprise Centre, Battlefield Enterprise References [38] S. Krug, J. R. G. Evans, J. H. H. TerMaat, Journal of the European Ceramic Society, vol.22, 2002, Pages: 173-181. Fax to: +44 (0) 1743 469 909 Park, Shrewsbury SY1 3FE, United Kingdom [1] M. Flinders, D. Ray, A. Anderson, R. A. Cutler, Journal of American [39] T. Gietzelt, O. Jacobi, V. Piotter, R. Rupercht, J. Hausselt, Journal of Email: [email protected] Ceramic Society, vol.88, 2005, Pages: 2217-2226. Materials Science, vol.39, 2004, Pages: 2113-2119. [2] K. Pelissier, T. Chartier and J. M. Laurent, Ceramics International, vol. order online at Tel: +44 (0)1743 454990 24, 1998, Pages: 371-377. www.pim-international.com SEPTPIMI10

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