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in this issue Company profile: Inmatec Ceramics in luxury watches Additive Manufacturing of ceramics

Published by Inovar Communications Ltd www.pim-international.com Publisher & editorial offices Inovar Communications Ltd 2 The Rural Enterprise Centre Battlefield Enterprise Park Shrewsbury SY1 3FE, United Kingdom Tel: +44 (0)1743 454990 Fax: +44 (0)1743 469909 Email: [email protected] Web: www.pim-international.com

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

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

Consulting Editors Professor Randall M German A bright future for Ceramic Associate Dean of Engineering, Professor of Mechanical Engineering, San Diego State University, USA Injection Moulding Dr Yoshiyuki Kato Kato Professional Engineer Office, Yokohama, Japan Professor Dr Frank Petzoldt In the world of product design and engineering, the Metal Deputy Director, Fraunhofer IFAM, Bremen, Germany Injection Moulding (MIM) industry still has a long way to go in Dr David Whittaker order to achieve high levels of awareness amongst designers DWA Consulting, Wolverhampton, UK and engineers. The situation is in some respects even more Bernard Williams challenging for Ceramic Injection Moulding (CIM), where there is Consultant, Shrewsbury, UK not only a limited awareness of the process itself, but also a more Production general misunderstanding of the properties and capabilities of Hugo Ribeiro, Production Manager technical ceramics. Tel: +44 (0)1743 454990 Email: [email protected] With this issue of PIM International, which will be distributed Advertising widely at Ceramitec, the leading international ceramics exhibition Jon Craxford, Advertising Director held in Munich, Germany, October 20-23, we hope to make a Tel: +44 (0) 207 1939 749, Fax: +44 (0) 1743 469 909 E-mail: [email protected] small contribution towards addressing this issue. For those who are new to Ceramic Injection Moulding, the technology is by no Subscriptions means new. Early versions of the process date back to the 1930s Powder Injection Moulding International is published on a quarterly basis as either a free digital and 1940s, however since the late 1970s technical advances have publication or via a paid print subscription. The enabled a much wider use of the technology. annual print subscription charge for four issues is £135.00 including shipping. Rates in € and US$ are Today CIM applications can be found in the automotive, aerospace, available on application. 3C, medical and dental sectors, to name just a few. Wherever Accuracy of contents high precision, complex shaped components are required in high Whilst every effort has been made to ensure the volumes and with unique properties such as high wear, corrosion accuracy of the information in this publication, the publisher accepts no responsibility for errors or heat resistance, CIM products can be used. or omissions or for any consequences arising there from. Inovar Communications Ltd cannot be As we discover in this issue, the appeal of CIM has rapidly spread held responsible for views or claims expressed by beyond industrial applications. CIM watch cases and components contributors or advertisers, which are not necessarily those of the publisher. have become hugely popular with many of the world’s finest watchmakers thanks to the material’s high strength, toughness Advertisements and hardness combined with the precision and net-shape abilities Although all advertising material is expected to conform to ethical standards, inclusion in this of the CIM process. Additionally, the material’s low thermal publication does not constitute a guarantee or conductivity makes it very comfortable against the skin, and a endorsement of the quality or value of such product high refractive index allows for beautiful surface finishes to be or of the claims made by its manufacturer. achieved. Reproduction, storage and usage Worldwide Single photocopies of articles may be made for Nick Williams Global manufacturer of nodular and spherical aluminum powders, personal use in accordance with national copyright Managing Editor pre-alloyed aluminum powders, and aluminum premixes for PM laws. All rights reserved. Except as outlined above, no part of this publication may be reproduced or www.ampal-inc.com www.poudres-hermillon.com transmitted in any form or by any means, electronic, photocopying or otherwise, without prior permission of the publisher and copyright owner. Cover image In the Americas Compounded CIM feedstock Supplier of carbonyl iron and atomized stainless steel powders for Printed by (Photo courtesy Inmatec Cambrian Printers, Aberystwyth, United Kingdom the PM and MIM industries Technologies, Germany) ISSN 1753-1497 (print) United States Metal Powders, Incorporated ISSN 2055-6667 (online) 408 U.S. Highway 202, Flemington, New Jersey 08822 USA Vol. 9. No. 3 September 2015 Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 email: [email protected] © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 1

USM 2013 PM Review and PIMI.indd 2 16/01/2013 10:41:40 YOUR ONE-SOURCE for METAL INJECTION MOLDING September 2015 Rapid Prototyping through Mass Production

8 49 57 63 76 In this issue

43 Inmatec Technologies: A feedstock 73 Additive Manufacturing of Ceramics: supplier at the forefront of CIM technology Opportunities and solutions for the CIM Ceramic Injection Moulding has come a long way industry in recent years, with the industry blossoming from The Additive Manufacturing of ceramics has the the manufacture of simple engineering components potential to not only transform the way the ceramic to the production of advanced dental implants industry addresses prototype development, but also and beautiful watch components for the world’s presents an opportunity to open up new applications Complex precision components. most prestigious luxury brands. As Dr Georg that until now were impossible to produce with Schlieper reveals, behind this success are specialist conventional ceramic technology. Dr Johannes Homa feedstock producers such as Germany’s Inmatec and Dr Martin Schwentenwein present the state of Technologies. the art in ceramic AM and review the technical and commercial considerations with specific relevance to 53 Ceramic Injection Moulding adds to the CIM community. the allure of luxury watches Recent years have seen an increasing number of 81 POWDERMET 2015: Advances in MIM leading luxury watchmakers embracing Ceramic materials and processing highlighted Injection Moulding for watchcases, bezels, bracelet in San Diego segments and even movement parts. We report on POWDERMET2015, which took place in San Deigo, ISO 9001:2008-Certified From concept through design and development, to prototypes and, finally, mass ISO/TS 16949-Certified recent Ceramic Injection Moulded applications from California, from May 17-20, continues to encourage production, ARCMIM utilizes advanced manufacturing technologies to provide full-service, AS 9100-Certified the luxury market. MIM producers, industry suppliers and researchers ISO 13485-Certified from around the world to share their latest research quality solutions with accelerated timelines. 63 Micro Powder Injection Moulding: and developments. Dr David Whittaker reviews a As a full-service MIM provider, ARCMIM offers its customers the convenience, efficiency, quality Processes, materials and applications selection of papers that reflect a number of key and cost advantages inherent with a one-source partner. As a MIM veteran – and technology Micro Powder Injection Moulding (MicroPIM) areas for MIM process enhancement and industry leader – ARCMIM ensures the precision, ingenuity, product efficacy and superior quality necessary continues to attract attention as a unique process growth. in today’s competitive marketplace. We support and provide our customers with: by which to manufacture metal and ceramic micro > Metal injection molding components in medium to high volumes. In the exclusive review for PIM International magazine Dr > Plastic injection molding Volker Piotter and Dr Tassilo Moritz present a status Regular features > Magnesium injection molding report on the technology, from binder developments > Medical cleanroom molding to best practice in process simulation, injection 4 Industry news > 3D printing in metal and plastic moulding and sintering. A number of innovative 96 Events guide, Advertisers’ index application areas are also reviewed. > State-of-the-art tool center > Custom hermetic seals, flanges and fittings > World-class facilities in USA and Europe Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 3 DiscoverContact us the to day!ARCMIM Europ Advantagee: +36 35 551 – Contact 000 Unit use dtoday! States: 303-833-6000 www.arcmim.com Industry News | contents page | news | events | advertisers’ index | email |

Industry News High-Temperature Retort Furnaces To submit news for inclusion in Powder Injection Moulding International please contact Nick Williams, [email protected]

Hoeganaes Corporation introduces metal powders for MIM and Additive Manufacturing

Hoeganaes Corporation, based in in conjunction with a multi-million Cinnaminson, New Jersey, USA, has dollar expansion of its Innovation launched AncorAM™, a new product Center in Cinnaminson. Additions line of metal powders engineered for to the research and development advanced forming processes including facility include a new Advanced PM AncorTi is a spherical powder for Additive Manufacturing, Metal Machining Lab and 3D printer. Chief applications in Additive Manufac- Injection Moulding, and Hot Isostatic among the technological upgrades is turing, MIM and HIP Pressing. The first offering in this a pilot atomising facility dedicated to series includes AncorTi™ titanium the development of advanced metal Metallurgy. The company is a leading powder, a spherical powder available powders. contributor to the approximately one in Ti6Al4V alloy and commercially A leader in the development million metric tons of iron powder pure grades. Ti6Al4V alloys exhibit and production of ferrous powders used to produce press-and-sinter a high strength to weight ratio primarily for automotive and indus- parts worldwide. with excellent corrosion resistance trial applications, Hoeganaes stated Hoeganaes is already collaborating and biocompatibility. This range of that its investment provides the basis with new customers to supply AncorTi properties makes the alloy a perfect for long-term growth in new arenas, for aerospace applications using candidate to manufacture parts for including the aerospace and medical Additive Manufacturing. For more VHT 500/22-GR aerospace, medical, chemical and industries. information on AncorAM solutions, marine applications. For over 65 years Hoeganaes contact Paul Taylor, Standard sizes 8 to 500 l Hoeganaes has taken this step has been a major part of the global [email protected]. into the specialist powders market landscape in conventional Powder www.hoeganaes.com Tmax 1200 °C - 2400 °C Graphite, molybdenum, tungsten or molybdenum disilicide heating Operation under vacuum, protective, or reactive gases Certified safety system with fail-safe PLC for working under hydrogen Graphic touch panel as operator interface

CIM and MIM sintering furnaces available. More information, see catalog „Advanced Materials“!

EuroPM Ceramitec Reims/France Munich/Germany October 04-07, 2015 October 20-22, 2015 Made Booth 88 Hall A2, Booth 201/302 in www.nabertherm.com Germany 4 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Headquarters: Nabertherm GmbH . 28865 Lilienthal/Bremen, Germany . Tel +49 (4298) 9220 . Fax 129 . [email protected]

MIM specialist ARC Group further expands its Additive Manufacturing capacity

ARC Group Worldwide, Inc., a powder metals to increase capacity leading international MIM parts and develop new materials not producer with operations in the USA currently being offered,” stated Ashley and Europe, has announced that its Nichols, General Manager of 3DMT. 3D printing/Additive Manufacturing “Notably, we will be working on division, 3D Material Technologies, new aluminium alloys, as well as high LLC, (3DMT) has further expanded strength, high temperature ferrous its metal Additive Manufacturing alloys, which are of great interest to capacity with the purchase of new our customers. We have been quite machines from Concept Laser and encouraged by this recent increase EOS. in adoption of metal 3D printing by The new machines, a Concept clients who traditionally used legacy Laser M2 Cusing 400W Dual Laser manufacturing processes, and believe and an EOSINT M280, will add to this is potentially indicative of the 3DMT’s already significant metal 3D future market opportunity that addi- printing experience and capacity, as tive metals may have,” added Nichols. well as its leading plastic 3D printing Overall, these additional machines capabilities. will significantly increase 3DMT’s “We have recently experienced capacity and reduce lead time to increased demand for our Additive support customers in the aerospace, Metal/3D printing services from the defence, dental, and medical indus- aerospace industry, Department of tries, as well as in ARC’s Metal Injec- Energy, Department of Defence, and tion Moulding, injection moulding, medical device markets, which led tooling, and various capabilities. us to purchase these new machines. Further, these new machines have the Further, with production jobs from capability of making a wide variety of our existing customers tying up parts out of Inconel 625, Inconel 718, significant existing capacity, the titanium, aluminium, stainless steel, additional equipment allows us to cobalt chrome, and maraging steel. continue to use our expertise in www.3dmaterialtech.com

World PM2016 Congress & Exhibition: Call for Papers issued

The World PM2016 Congress & A Call for Papers has now Exhibition, organised and sponsored been issued and abstracts can be by the European Powder Metal- submitted online until November 12th lurgy Association (EPMA), will take 2015. World PM2016 is an all topic place in Hamburg, Germany, from event and includes sessions on: October 9-13, 2016. • Additive Manufacturing The Powder Metallurgy World Congress is held in Europe once • Hard Materials and Diamond Tools every six years and is therefore an • Hot Isostatic Pressing essential destination for those in • New Materials and Applications the international PM community to meet suppliers, producers and • Powder Injection Moulding end-users and to discover the latest • PM Structural Parts innovations in the state-of-the-art PM technology. www.worldpm2016.com

EPSON ATMIX CORPORATION Advanced Materials Technologies European PM and diversifies with new 3D metal MIM sectors see printing centre continued growth

Advanced Materials Technologies The European PM industry is Pte Ltd (AMT), Singapore, has benefiting from the gradual economic announced that it is now offering recovery in Europe, and particularly metal Additive Manufacturing services from a rejuvenated automotive to complement its existing range industry over the past couple of years. of mass manufacturing processes. Both ferrous and copper-based The company specialises in the high powder shipments to the PM industry volume manufacture of complex were reported by the European precision components via Metal Injec- Powder Metallurgy Association tion Moulding and Ceramic Injection (EPMA) to have increased by 7.1% in Moulding. 2014 compared with the previous year In addition to prototyping parts, to over 197,612 tonnes. AMT stated that it is also leveraging The EPMA expects this growth Finer Powder Production Additive Manufacturing technology trend to continue for 2015 with an to meet demands for small volume anticipated 5% increase for PM batch production. One of the main Having established a 3D Metal powder shipments over the whole Cleaner Powder Production advantages of 3D metal printing for Printing Centre, AMT is able to offer year. The MIM sector is also reported small volume production is the poten- a complete solution to customers by the EPMA to have put in another Shape Control of Powders tial elimination of tooling. This leads seeking to accelerate their develop- steady performance in 2014 gaining to direct production being possible ment of ideas and translation into by around 10% by sales value to an without costly and time-consuming final product. estimated €280 million ($310 million). tooling. www.amt-mat.com www.epma.com

• Low Alloy Steel • High Alloy Steel • Stainless Steel • Magnetic Materials • Granulated Powder

JAPAN Mr. Numasawa, Ryo [email protected] U.S.A and SOUTH AMERICA Mr. Pelletiers, Tom ASIA and OCEANIA [email protected] Mr. Yoshida, Shunsuke [email protected] EU Dr. Pyrasch, Dieter CHINA [email protected] Mr. Ota, Arata [email protected] KOREA Mr. Yun, John 8 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 [email protected] Industry News | contents page | news | events | advertisers’ index | email |

The function of this MicroMIM Miniature metal check valve made by check valve component is to control Micro Metal Injection Moulding the flow of blood to the heart, however the design is not limited to A check valve is a valve that what the company claims is the just medical applications but also normally allows fluid, be it liquid world’s smallest MIM-made metal to other industries. Fig. 1 shows the or gas, to flow through it in only check valve at the 6th Medical internal structure of the check valve one direction. In some check valves Equipment Exhibition held in and its operation in the ‘stopped’ Metal Injection Molding a spherical ball is used to block Tokyo, June 24-26, 2015, using its and ‘flowing’ states. Fig. 2 shows the or release the flow. Japanese MicroMIM technology. The check MicroMIM check valve and its inner Metal Injection Moulding (MIM) valve has a diameter of just 2.4 mm structure. New grade available: producer Taisei Kogyo Co. Ltd., and wall thickness of 0.2 mm, which Taisei Kogyo reports that it based in Neyagawa City, Osaka is considered to be the limit of has been successful in the series Prefecture, recently introduced conventional MIM technology. production of the small part having such a highly complex internal shape ® thanks to its expertise in MicroMIM. Catamold 17-4PH Plus The company states that such a complex shape would be impossible to machine, and some of the internal features would also be impossible without Metal Injection Moulding. www.metal-injection-tech.com Feedstock from Feedstock ideal for: World-Scale Plant: ■ high capacity ■ ICT applications ■ short lead times ■ Consumer goods ■ competitive price ■ Various part sizes & shapes

Spec: 400-1000 g/10min (190°C; 21.6kg); 1.1629 – 1.1710; >7.60gcm-3

Fig. 1 Image of the inside of the check valve in operation, above is when it is ‘stopped’ and below is when it is ‘flowing’

150 years

Fig. 2 Appearance and inner struc- [Catamold® - inject your ideas] ture: the thickness of 0.2 mm is only possible only with MicroMIM www.catamold.de

european powder metallurgy association

differences in wall thicknesses Advanced Registration Deadline 14 August 2015 Novel PIM method developed required in the various membrane International Congress & Exhibition carrier combinations. 4 - 7 October 2015 for manufacture of integrative Reims Congress Centre, France Dr Volker Piotter and his membrane carriers colleagues at KIT reported in the Credit © Federal Mogul © Federal Credit May 2015 issue of Microsystems The mass production of carrier capable of volume production is Technologies (Vol. 21), that in order VISIT US AT PM2014-wildbild © Euro Credit devices incorporating membranes required. to produce the integrated membrane as quasi-monolithic devices is often Researchers at the Institute of carriers containing different wall

Developing the Powder Metallurgy Future Metallurgy Future the Powder Developing www.europm2015.com problematic, and a way to produce Applied Materials at the Karlsruhe thicknesses, a demonstrator tool STAND@Euro_PM #EuroPM2015 92 these devices as an integrated Institute of Technology (KIT) in design was developed. This tool product would offer distinct economic Eggenstein-Leopoldshafen, Germany, design enabled the generation of thin advantages. As these membrane have adapted micro powder injection membranes by a controlled piston devices are made from both plastic moulding technology developed previ- movement in the injection moulding and also metals and/or ceramics, ously at KIT to overcome problems in step. Simulation calculations were a suitable manufacturing method producing µPIM parts with significant used to determine the layout of the runner system, and the resulting filling behaviour and dimensional accuracies of the moulded parts. The twin-piston moulding tool also enabled the subsequent embossing of the moulded feedstock in the membrane cavity which allows further consolidation and results in a defined adjustment of the membrane MIM debind and sinter thickness in the range from 600 µm to less than 200µm.The combined injection + embossing process could vacuum furnaces further reduce minimum membrane thickness by a half. Over 6,500 production and laboratory furnaces manufactured since 1954 www.kit.edu

• Metal or graphite hot zones • Processes all binders and feedstocks PIM International • Sizes from 8.5 to 340 liters On the leading edge of (0.3–12 cu ft.) magazine’s digital • Pressures from 10-6 torr to archive expanded 750 torr metal powder manufacture • Vacuum, Ar, N2 and H2 The free-to-access • Max possible temperature digital archive of 3,500°C (6,332°F) past issues of PIM With over 35 years’ experience in gas atomisation, Sandvik Osprey offers • Worldwide field service, International maga- the world’s widest range of high quality, spherical metal powders for use in rebuilds and parts for all zine has recently been makes Metal Injection Moulding. Our products are used in an increasingly diverse expanded to included range of applications including automotive, consumer electronics, medical every issue dating and aerospace. MIM-VacTM back to March 2013. The recent additions include ® Our extensive product range includes stainless steels, nickel based Injectavac all issues from 2013 (Volume 7) Centorr Vacuum Industries, Inc. and feature a number of exclusive superalloys, master alloys, tool steels, cobalt alloys, low alloy steels and 55 Northeastern Blvd company profiles including Element binary alloys. Nashua, NH 03062 USA 22, CMG Technologies, Maxon Tel: +1 603 595 7233 Fax: +1 603 595 9220 Motor, Elnik Systems and Polymer Using gas atomised powders can enhance your productivity and profitability: Email: [email protected] Technologies Inc. Past issues can contact our technical sales team today for more information. be downloaded in a convenient PDF format. www.pim-international.com Hall A2 www.centorr.com/pi Stand 104

Sandvik Osprey Limited 12 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Milland Road Neath SA11 1NJ UK Phone: +44 (0)1639 634121 Fax: +44 (0)1639 630100 www.smt.sandvik.com/metalpowder e-mail: [email protected]

The Hot Isostatic Pressing (HIP) 3D Printing with Binder Jetting Technology Positive outlook for North American market registered gains last year MIM and HIP industries that should continue into 2015. “The use of PM HIPed products for the In his state of the PM industry keynote industrial, 24%; medical/dental, 19%; oil-and-gas market will increase, presentation at POWDERMET2015, automotive, 15 %; electronics, 9%; despite declines in oil drilling and San Diego, USA, May 18 2015, Richard and miscellaneous, 5%. fracking. This is mainly due to long Pfingstler, President of the Metal Pfingstler stated, “While the lead times for necessary replacement Powder Industries Federation, stated firearms market currently remains parts. HIPed PM aerospace parts that despite some “bumps in the MIM somewhat sluggish, it will most likely are another growing market,” stated business road,” namely the saturated stabilize into a more normal growth Pfingstler. firearms market, 2014 was a good pattern. However, overall the MIM HIP densification of MIM parts year for the North American MIM industry is set to enjoy a 10% growth remains a robust growth business, industry. He added that the forecast rate in 2015, certainly an enviable and there is new interest in HIP from for the next three to five years also position.” the Additive Manufacturing sector. looks positive. The Metal Injection Moulding “Additive Manufacturing offers an According to a 2014 survey by the industry has begun selling into the exciting niche business for PM and Metal Injection Molding Association automotive market in North America, metal powder producers. Without (MIMA), the MIM industry is still following the trend in Europe towards a doubt AM presents some very ascending its growth-cycle curve at the adoption of MIM automotive interesting opportunities as a new PM a growth rate well above that of the components. “Automotive engineers technology.” GDP. Some, it was stated, have even are designing more MIM parts, which It was stated that a number of suggested that the industry is still in points to significant potential growth powder makers are working on the steepest segment of its growth as MIM becomes more accepted. qualifying gas and water atomised curve. The MIMA survey reported the MIM parts are being designed for powders for AM applications made following primary end-user markets engines, electrical systems, and by laser-based, electron-beam, and in North America by weight of parts chassis hardware,” concluded ink-jet processes. shipped: firearms, 28%; general Pfingstler. www.mpif.org

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warehouse. In relation to the and MIM to 7,000 m². Artur Gevorkyan GmbH, a new furnace for special Slovakian MIM producer Gevorkyan to enlargement of the MIM operation, commented that the company intends materials from Elnik Systems, as new investments have been made in to remain reasonably independent of double the size of its operation well as injection moulding machines the company’s quality department, the automotive industry, maintaining from Arburg GmbH + Co KG. The where 3D inspection technology and automotive production at 30% of its Gevorkyan, s.r.o., is a family owned remaining 30%. These figures, stated company is also installing a HIP equipment for the chemical analysis total portfolio. The company plans to Powder Metallurgy producer estab- the company, are steering investment plant which will primarily be used for of materials have been installed. change from present sales ratio of SmartPower lished 20 years ago in Slovakia by plans. parts destined for the firearms and The company has its own tool room, 85% PM and 15% MIM technology to Armenian military aircraft engineer This year, the company has aerospace industries. servohydraulic excellence where two CNC Hermle mills and 50% PM and 50% MIM, as well as to Artur Gevorkyan. Today, the company invested in a new MIM continuous Over the last year, the company Fanuc electro-erosion machines are increase sales from the present €20 supplies PM and MIM parts to a debinding and sintering furnace from has taken on 70 new employees installed. million to €40 million by the end of wide range of end-user industries Cremer Thermoprozessanlagen and built a new fully-automated In Gevorkyan’s R&D department, 2018. The majority of the company’s including the automotive, oil and 50% of the company’s engineers customers come from Europe and gas, hand tools, locks and garden work exclusively on MIM technology. North and South America. equipment sectors. By the end of 2015, the company The company actively promotes Over the last three years the plans to install a 3D printer as well MIM technology to its customers, with company has not only invested in as software for the simulation of technical days organised at Gevorkyan the modernisation of its PM opera- the injection moulding process. as well as at customers’ plants. tions, but has also established a The company currently offers rapid Together with increasing sales and a new MIM division. Artur Gevorkyan prototyping of MIM parts by CNC growing workforce, Artur Gevorkyan’s told PIM International that the machining samples from feedstock told PIM International that his goal development of MIM technology blocks. “This is desired mainly by is to keep the special atmosphere of was an important strategic target customers, who do not have any a family company with close relation for next decade. Around 70% of experience with MIM materials,” between employees and customers, new company projects are already 25 – 120 t stated Artur Gevorkyan. where everyone is willing to help coming from MIM customers, with In last twelve months, Gevorkyan and exceed customer expectations. conventional PM accounting for the Engineering discussions at Slovakian MIM specialist Gevorkyan, s.r.o has received 73 new tooling orders The company recently received a for MIM projects. The company Best Employer award from Via Bona plans to add an additional 3,500 m² Slovakia. For more information email: of floorspace to its MIM production [email protected] facility, bringing the total area for PM www.gevorkyan.sk spacious

Summer 2015 issue of Metal compact Additive Manufacturing e cient magazine now available to download

The latest issue of Metal Additive • Advances in aerospace applica- Manufacturing, the quarterly maga- tions: MTU produces Airbus A320neo borescope bosses with zine for the metal AM industry, is now Hall B1, Booth 1204 Additive Manufacturing available to download from the publi- October 13 - 17, 2015 cation’s website. Available in both • AMPM2015 conference report: Friedrichshafen, Germany print (ISSN 2057-3014) and digital Innovative materials, powder (ISSN 2055-7183) formats, Metal characterisation and metallo- Additive Manufacturing magazine graphic testing brings together industry news and • Rapid.Tech 2015: Germany’s articles on technical and commercial conference and exhibition on AM targets an international audience developments in the industry. In addition to a comprehensive 31 page • Concept Laser’s QMmeltpool 3D: industry news section, this 72 page In-situ quality assurance with real-time monitoring down to the issue includes the following articles micron level. and reports: Headquarters: A free digital issue in PDF format WITTMANN BATTENFELD GmbH • Additive Industries: Moving is available to download from the Wiener Neustädter Straße 81|A-2542 Kottingbrunn towards automation and Tel.: +43 (0) 2252 404-0|Fax.: +43 (0) 2252 404-1062 magazine’s website. integration in metal Additive [email protected] Manufacturing www.metal-am.com

CMG believes that whilst 3D metal printing UK MIM producer CMG technologies are developing at an extraordinary rate, Technologies targets users of metal there are currently still limitations as to their capabilities. The technology is still predominantly used for 3D printing technology prototype production as the technology is not yet fast enough to cope with mass production. 3D metal CMG Technologies, the UK’s leading manufacturing industry. The term 3D printing can also only be used to produce components Metal Injection Moulding specialist, printing has captured the attention of from a relatively small selection of materials. states that it has trademarked the both industry and the general public “Rather than being seen as a competitor to 3D term ‘CMG Technologies 3D Metal and this, we believe, coupled with metal printing, MIM can actually provide the stepping Moulding®’ as part of the company’s significant developments in tech- stone needed between prototype and volume produc- efforts to raise awareness of the nology which reduced both the size tion. Once the initial tooling is complete we are able to scope of opportunities offered by and costs of 3D printing machines, Scalpel handles manufactured by deliver huge volumes of parts in a far wider variety of Mechanical bracket MIM. The company believes that has played a vital role in the process CMG Technologies prior to debinding materials than is currently possible with 3D printing,” for a satellite to be whilst more and more manufacturers gaining widespread understanding.” Garrett stated. CMG added that its MIM facility is and sintering used in the space most effective for small, complex components in are becoming familiar with the CMG is hoping to replicate the sector produced on a capabilities of metal 3D printing/ success of this transition for Metal it is that CMG Technologies actually annual volumes of 1000 or more, although if the part Renishaw AM250 Additive Manufacturing, the process Injection Moulding. MIM is still a rela- does,” explained Garrett. “Whilst is particularly complex and expensive the process and benefits offered by Metal Injection tively new industry and a significant the term Metal Injection Moulding could still be cost effective for volumes of 500 or Moulding are less well-known in the number of companies that need to describes the process well, it is not more. Globally, MIM technology providers can deliver UK. procure complex metal components always exactly clear what the outcome extremely high volumes of a complex 3D part, with CMG’s Technical Sales and may not be aware of its existence, let is - 3D parts moulded from metal. To some components being produced at a rate of several Marketing Director, Rachel Garrett, alone the savings they could make those involved in this industry like we million parts per month for sectors such as consumer stated, “Although 3D printing has in terms of cost, lead times and are, this sounds obvious, but to people electronics. Parts can be produced from a wide range been around for more than 30 years, environmental impact. unfamiliar with MIM hopefully this of materials including titanium and precious metals, it is only in recent years that it has “The phrase ‘3D metal moulding’ term makes it easier to understand making the process particularly attractive for manu- become widely recognised in the paints an immediate picture of what what we do.” facturing parts used in the aerospace and medical devices sectors. Redefine www.cmgtechnologies.co.uk your design India’s SRPM begins MIM grade powder production

Shree Rajeshwaranand Paper Mills Ltd (SRPM), located in Gujarat, India, has announced a move into metal powder production. In addition to being one of India’s leading paper products manufacturers, the Explore the potential of additive company has diversified into manufacturing resin manufacturing bond, ceramic bond and metal bond grinding wheels and a range of metal powders. SRPM announced that it has established a state of Renishaw’s additive manufacturing systems use powder bed fusion the art manufacturing plant with the necessary quality technology to produce fully dense complex metal parts direct from control systems including AAS, FSSS, SEM, laser 3D CAD. particle analyser, etc. The company began production Don’t be constrained by traditional manufacturing design rules. in March 2015 and offers special grades of preal- Create complex geometries such as conformal cooling channels for loyed powders suitable for Metal Injection Moulding, tooling inserts, reduce component weight, and consolidate multiple Diamond Tools and other Powder Metallurgy applica- parts in one assembly. tions. The range also includes cobalt, tungsten, iron and nickel metal powders. • No requirement for tooling. SRPM was established in 1995 and employs around • Increased design freedom - complex geometries and hidden 250 staff. The company’s Managing Director, Prakash features. Vora, added that further expansion of all its current • Rapid design iterations right up to manufacture. Jiangxi Yuean Superfine Metal Co., Ltd YUELONG GmbH US Distributor activities will begin in the near future. Tel: +86 797 8772 869 Fax: +86 797 8772 255 Tel: +49 6074 9147 933 United States Metal Powders, Inc. shreerajeshwaranandgroup.com Xinhua Industrial Park, Dayu County, [email protected] Contact: Rhonda Kalser Jiangxi Province [email protected] For more information visit www.yueanmetal.com Tel: +1 908 782 5454 www.renishaw.com/additive

18 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 19

Arburg to focus on part quality at Bodycote’s APMA International Conference Euro PM2015 Jane LaGoy on Powder Metallurgy: Technical

In a presentation at the Euro PM2015 equipped laboratory in which new recognised with Programme now available Congress and Exhibition, Reims, application areas for the PIM process ASTM President’s France, October 4-7 2015, Marko are continuously being developed. All The Technical Programme has Metallurgy Association (JPMA), Maetzig, who is responsible for upstream and downstream production Leadership Award been published for APMA 2015, the event includes both oral and applications development at injection steps such as material preparation, the 3rd International Conference poster presentations along with an moulding machine producer Arburg debinding, sintering and part analyses Jane LaGoy, Technical Services on Powder Metallurgy in Asia. international exhibition. GmbH + Co KG, will examine the can also be tested there. Equipment Experts Marko Maetzig, Hartmut Manager at Bodycote in Andover, The event will take place in Kyoto, The official language of the relationship between mould tempera- includes a shear roll extruder, Walcher and Uwe Haupt (left to right) Massachusetts, USA, has received Japan, November 8-10, 2015. conference is English and early ture and PIM part quality. debinding systems, sintering ovens at Arburg's modern PIM laboratory. the 2015 ASTM International Presi- Organised by the Japan Society registration discounted offers are “Fluctuations in quality often arise and a device for simultaneous dent’s Leadership Award in recogni- of Powder and Powder Metallurgy available until September 30. during powder processing, leading thermal analysis. This comprehensive Moulding and a position-regulated tion of her work for ASTM’s Metal (JSPM) and the Japan Powder www.apma2015.jp to variations in part properties,” range is complemented by automa- screw. Powders Committee. The President’s stated Maetzig. “A constant green tion solutions, application-specific The products produced on the Leadership Award recognises compact density should be strived consulting and special PIM training company’s Allrounder injection individuals early in their ASTM career for in order to avoid time-consuming courses. moulding machines range from who have significantly advanced tests and costly mould modifications.“ Arburg states that fundamentally, micro gear wheels with an external our mission through extraordinary Congress participants will discover the same machines used in plastics diameter of 1.4 mm to ceramic cores accomplishment, example and how this can be achieved through processing are also used for Powder for stationary gas turbines weighing vision. It is presented annually to complete pressure compensation Injection Moulding. However, the up to two kilograms. New materials, two deserving ASTM members. This in the moulded part and how the Allrounder machines for PIM mould and machine technology are year’s other recipient is Kent Lowry, company’s Variotherm process can processing feature special equip- opening the door to a growing number M.D., an orthopedic surgeon at contribute to this. ment such as a highly wear resistant of innovative PIM applications in a Northland Orthopedic Associates in Arburg, headquartered in Loss- cylinder module, a special screw diverse range of industries. Rhinelander, Wisconsin. burg, Germany, has an extremely well geometry adapted to Powder Injection www.arburg.com LaGoy, who joined ASTM in 2010, is a very active member of Euro PM2015 Committee B09 on Metal Powders Reims / France and Metal Powder Products. She 5-7 October 2015 ec 2015 currently serves as B09 secretary Ceramit and chairs Subcommittee B09.05 Munich / Germany on Structural Parts. She has been 20-23 October 2015 instrumental in the development of and revisions to several key ASTM standards for the Powder Metallurgy industry during her short tenure. LaGoy also works on Committees A01 on Steel, Stainless Steel and Related Alloys, B07 on Light Metals and Alloys, and F42 on Additive Manufacturing Technologies in addition to B09. A graduate of Rensselaer PM Tooling System Polytechnic Institute, Troy, New York, where she received a bachelor’s The EROWA PM tooling system is the standard degree in materials engineering, interface of the press tools between the LaGoy earned her MBA from Rivier College in Nashua, New Hampshire. toolshop and the powder press machine. She has worked at Bodycote since Its unrivalled resetting time also enables 1992 as an engineer, metallur- gist and lab manager, assuming you to produce small series proﬁ tably. her current role in 2013. LaGoy specialises in Hot Isostatic Pressing www.erowa.com (HIP), materials characterisation and Powder Metallurgy. www.astm.org

Hagen Symposium to focus Copper-polymer bullets made by on process efficiencies and injection moulding special properties of PM The firing of small arms ammunition strength polymer binderwhich the materials for training, sport, law enforcement, company has designated Cu/PTM. and military purposes is a significant The Cu/P projectiles are lighter and The Fachverband Pulvermetallurgie (FPM), the German source of environmental pollution. faster than lead, are environmentally trade association for Powder Metallurgy, has published The ammunition for small arms is safe and range compliant. They the technical programme for the 34th Hagen Symposium normally made from high density are produced by PolyCase using a scheduled to take place in Hagen, Germany, November metals such as lead and its alloys, fully automated injection-moulding 26-27, 2015. which are traditionally shaped by process and loaded to SAAMI INCPTR-Ammo6-CU1-5784 ammu- The programme will embrace a wide range of PM casting or by cold forming where the specifications in high quality brass nition made by injection moulding processes such as rapid sintering, Additive Manufac- metal is shaped in dies to create the cases. of a copper-polymer compound by turing, trends in hardmetal cutting tools, advanced PM projectile shape. Powder Metallurgy PolyCase founder and CEO Paul PolyCase Ammunition aerospace alloys, ferrous structural parts, powder forged has also been used to produce Lemke stated that by using injection steels, magnetic materials and ceramics for filtration non-sintered lead-free bullets where moulding of the copper-polymer applications. Around 60 organisations from industry and the frangible, or “soft”, rounds are mixture, the company has been able close range training. research are expected to take part in the exhibition which designed to break apart when they to produce bullets with a number of The injection moulding process will run alongside the symposium. hit walls or other hard surfaces advantages. For example, the Cu/P used by Polycase is said to have fewer The symposium will include the presentation of the to prevent ricochets during close- bullets can weigh up to 30% less weight variations compared with cast Skaupy Prize to Austrian scientist Professor Wolf-Dieter quarters combat. than lead bullets with similar profiles lead bullets and ensures excellent Schubert who heads the Research Group on the Metal- Early in 2015 PolyCase Ammuni- and being lead free they are more concentricity. The process also allows lurgy of the Less Common Metals at the Institute of tion of Savanah, Georgia, USA, environmentally friendly. Lighter unique shapes to be produced which Chemical Technology and Analytics, Vienna University of introduced a range of patent-pending bullet weight also means higher would not be possible with conven- Technology. lead-free projectiles using a copper velocity, less recoil and low ricochet tional processes. Professor Schubert, who has devoted much of his alloy powder combined with a high- – all important qualities for indoor or www.polycaseammo.com working life to researching metallurgical aspects relating to tungsten carbide based hardmetals, will present his Skaupy Lecture on ‘Ultra-fine grain hardmetals – from powder to sintered tools’. The lecture will cover powder production, the selection of grain growth inhibitors, ® alternative consolidation processes for ultra-fine grain EMBEMOULD hardmetals, and examples of applications. www.pulvermetallurgie.com Powder Metallurgy Day MIM feedstock | MIM & CIM binders at Ceramitec to focus on Additive Manufacturing At eMBe we have the products and services EMBEMOULD® C AND EMBEMOULD® K 83 to help you “shape up” your metal or ceramic MIM and CIM binders for water and solvent debinding Ceramitec 2015, the international trade show for the powders, from binders for solvent and catalytic ® entire ceramics industry, ranging from conventional debinding to ready-to-mould feedstock. EMBEMOULD FEEDSTOCK MIM feedstock for solvent or catalytic debinding ceramics and raw materials to technical ceramics and Develop your products with us by using our in- Powder Metallurgy, will take place at Messe München, house laboratory and extensive experience as EMBELUBE® Munich, Germany, from 20 to 23 October 2015. one of Europe’s leading PM additive suppliers. Poreformers for PIM products with porosity The Supporting Programme will provide a platform for the transfer of knowledge and expertise in research Our services focus on product development and and development. Attendance to the specialist lectures product innovation to continuously meet our and panel discussions will be free of charge and simulta- customers’ evolving needs worldwide. neous translation in German and English will be offered for all lectures. This year’s programme will begin with eMBe Products & Service GmbH a panel discussion themed “ceramitec goes digital” on Gemeindewald 7, 86672 Thierhaupten, Germany the opening day, Tuesday 20 October 2015. Experts from Tel.: +49 8271 421988-3 Fax: +49 8271 421988-4 ceramics and Powder Metallurgy will report on progress [email protected] in Additive Manufacturing with regard to industrial reali- sation and further needs for research and development. www.embe-products.com www.ceramitec.de Embemould® and Embelube® are registered trademarks. Photo Arburg GmbH & Co KG

MIM industry recognised High Temperature in the 2015 MPIF Design Furnaces up to 3,000 °C Excellence Awards competition

The international Metal Injection Moulding industry once again accounted for a significant proportion of the winning parts in the Metal Powder Industry Federation’s 2015 Powder Metallurgy Design Excellence Awards competition. The winnsers were announced at Based on more than POWDERMET2015, San Diego, USA, May 17-20. 30 years of heat treatment experience Grand Prize Awards Fig. 1 A MIM bus nozzle manufactured by Advanced Fig. 2 Four MIM components made by Indo-US MIM Tec Carbolite Gero offer Automotive - Engine Materials Technologies Pte Ltd, Singapore, and used in a Pvt. Ltd and used in proportional valves found in hydraulic standard products as Advanced Materials Technologies Pte Ltd, Singapore, selective catalytic reduction system circuits of off-highway and farm equipment well as customer- earned the Grand Prize in the Automotive - Engine Category for a MIM bus nozzle used in a selective catalytic specific solutions. reduction (SCR) system of European commercial vehicles impossible to achieve using conventional machining. All Lawn & Garden/Off-Highway (Fig. 1). The nozzle performs the SCR function using urea internal channels are achieved through MIM, while the Four MIM components made by Indo-US MIM Tec Pvt. Ltd, n Furnaces for MIM and compressed air to reduce the NO produced during threads on top are machined and Micro TIG welding is Bangalore, India, namely a catcher, tension bar, base cap x and CIM production used to seal the small openings left by the polymeric and body, earned the Grand Prize in the Lawn & Garden/ combustion to N2 and H2O. and quality testing Made of an austenitic stainless steel (AISI HK30), the part insert; tip flatness is achieved through a grinding Off-Highway Category (Fig. 2). The components, made for n employs a patented technology that uses a removable operation. It is estimated that fabricating the nozzle Danfoss, Denmark, are used in proportional valves found Thermal or catalytic polymeric insert to form the highly complex internal through the welding/brazing of multiple parts would have in hydraulic circuits of off-highway and farm equipment. debinding without undercut channel, a feature the fabricator deems increased its cost by more than 200%. The two parts forming the new base are made of MIM the need for 17-4 PH stainless steel, while the catcher and tension condensate traps bar are formed of 4605 low-alloy steel. All dimensions of n Sintering furnaces the two parts forming the new base are achieved in the under partial as-MIM condition, including the internal thread in the pressure or low body. overpressure The catcher undergoes a grinding and burnishing SINTERING FURNACES process to attain the OD tolerance and surface finish, while the tension bar needs only a turning operation to form an external thread without a parting line. The parts were formerly produced via machining, welding, conventional PM, and fastening. By completely re-designing the parts to maximize the advantages MIM offers, the customer obtained savings estimated at 65%, with annual 60 bar Sinter - HIP System production of 350,000.

Hand Tools/Recreation Advanced Forming Technology, An ARCMIM Company, Longmont, Colorado, USA, was awarded the Grand Prize in the Hand Tools/Recreation Category for a breech block made for Smith & Wesson (Fig. 3). Fabricated via MIM from 4605 low-alloy steel, the block is inserted into the slide body of a .22 caliber pistol, creating the breech face and other critical functions. The unique geometry of the part, composed of two large masses separated by a channel running axially MIM System down the length of the part, creating two distinct bodies connected by very small ribs, presented a significant challenge to keeping the part together during sintering and maintaining tight final tolerances. The component was TAV SpA - Via dell'Industria, 11 - 24043 Caravaggio (BG) - ITALY - P +39 0363 3557 11 - www.tav-vacuumfurnaces.com manufactured net-shape with no secondary machining www.carbolite-gero.com operations; it is heat treated to a hardness range of

24 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 25

M M

Y Y

CM CM

MY Fig. 3 A breech block made for Smith & Wesson by Fig. 5 MIM lock parts made for Rutherford Controls Inc by Fig. 6 A MIM bolt manufactured by Indo-US MIM Tec Pvt. MY Advanced Forming Technology (AFT) Indo-US MIM Tec Pvt. Ltd. Ltd. and used in a Keystone Sporting Arms, LLC rifle CY CY

CMY CMY Hardware/Appliances Hand Tools/Recreation

K K Indo-US MIM Tec Pvt. Ltd received the Award of Distinction Indo-US MIM Tec Pvt. Ltd. received the second Award of in the Hardware/Appliances Category for two MIM 17-4 PH Distinction in the Hand Tools/Recreation Category for a stainless steel parts, front and rear keepers that go into 4605 low-alloy steel bolt (Fig. 6) used in the Crickett 22LR industrial electrical locks (Fig. 5), made for Rutherford rifle made by Keystone Sporting Arms, LLC. Made via MIM, Controls Inc. The parts’ complexity, with many cross holes the part replaced one produced by brazing together three and sharp knurl features, required the use of multiple machined parts, delivering an estimated 35% cost saving slides, some moving at different angles. The parts are in the process. The part’s design features many cross made close to net shape requiring only a final coining to holes and undercuts, requiring complex side core match- Visit us on adjust a small distortion and a tapping operation on the ings in the molding cavity. The fabricator delivers 60,000 www.me alinjectionmolding.it front keeper. Annual quantities are 20,000 per part. pieces annually.

Fig. 4 A MIM 4605 low-alloy steel top plate made for Multimatic Inmet, Canada, Indo-US MIM Tec Pvt. Ltd.

37–45 HRC, receives a black oxide finish and then Molding Metal undergoes a coining operation to qualify the width. The fabricator believes this is the first breech block fabricated using MIM, an indication that it is possible to expand the application boundaries for MIM even in a mature arena into Medals such as firearms. year after year after year... Awards of Distinction Automotive - Chassis Indo-US MIM Tec Pvt. Ltd. received the Award of Distinc- 18 MPIF awards since 1979 : tion in the Automotive - Chassis Category for a MIM 4605 low-alloy steel top plate (Fig. 4) made for Multimatic 9 Grand Prizes Inmet, Canada. The part goes into shock absorbers of 7 Awards of Distinction Chevrolet Camaro automobiles. The complexity of the part, with its 18 holes and six thin ribs that connect to 2 Awards of Achievement a ring around a central hole, presented a challenge to complete filling. The gating and venting system played a key role in producing this part defect free. It is produced close to (Photo courtesy of MPIF.org) net shape, with surface grinding to achieve flatness and a facing operation to achieve height tolerance being the only secondary operations performed. This application is a new design for MIM and delivers increased repeat- ability/accuracy of the shock absorber over the previous machined version, with estimated savings of 25%. www.parmatech.com 800-709-1555

26 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 27 Industry News | contents page | news | events | advertisers’ index | email |

Extensive services for Metal Injection Moulding INTRODUCING ELNIK’S from one source

TM Services  tool- and mouldmaking  metal injection moulding  toll debinding and sintering  thermal treatment incl. solid state nitriding  finishing processes

Customer Benefit  one-Stop procurement of ready to use metal CUTTING EDGE TECHNOLOGICAL ADVANCES THAT CAN SAVE YOU THOUSANDS $$ injection components Fig. 7 A MIM shell manufactured by Indo-US MIM Tec Pvt.  fast-track to market Ltd. for Hirose Korea Co. Ltd. The Metal Injection Molding process can be both risky and very costly unless you have a company like Elnik Systems  no preliminary investments in specialised industrial manufacturing equipment necessary working with you. The reason is simple. For over 18 years, Elnik Systems has made technological innovation its  no limitations regarding feedstock composition cornerstone. And innovative thinking leads to smarter MIM performance, we call “MIM-telligenceTM”.

Materials Taking it a step further, once Elnik innovates, extensive ﬁ eld testing is done before their new technology hits the market alloy steels, stainless steels, heat-resistant steels, tool steels, soft magnetic alloys, nickel- and cobalt- with the help of the full-sized production furnaces at DSH Technologies LLC, a research and development sister base alloys, copper and copper alloys company of Elnik. Elnik also offers free DSH services for one year with the purchase of each new piece of their equipment, providing every Elnik customer with additional customized technical support and dependability. Another Elnik “MIM-telligenceTM” beneﬁ t. www.mimpro.com INNOVATIVE SYSTEM FEATURES

Fig. 8 MIM connectors made by Indo-US MIM Tec Pvt. Ltd.  AccuTemp™ proprietary thermocouple control for Amphenol Air LB, France resulting in tight temperature control Tailor-made Feedstocks FROM EXPERTS FOR EXPERTS  Automatic Cleaning Features of binder

Electronic/Electrical trapping components and Dry Vacuum Pump. INMATEC Technologies GmbH Indo-US MIM Tec Pvt. Ltd. received two Awards of Ceramics – Ceramic Injection Moulding Distinction in the Electronic/Electrical Category. The  ColdFinger™ Debind Trap forced ﬂ ow Feedstock Development – Feedstock first award was given for a MIM 17-4 PH stainless steel enhanced binder trapping. Production – Quality Control shell (Fig. 7) made for Hirose Korea Co. Ltd. The part Consulting – Service goes into a charging assembly for mobile phones. The Mould construction  Gas Tight Retort Design Superior gas control complex geometry of the part, with thin cross sections throughout process zone, eliminating escaping and internal undercuts, was achieved with a slide-in-slide gas as compared to competitive designs. mechanism moving on specially designed cam tracks. The MIM part replaced an earlier design that used sheet  Laminar Gas Flow efﬁ cient and effective gas metal processing and welding, with an estimated 20% management for debinding and sintering. cost savings. Two million of the parts are delivered each month.  Simple Ease of Use PLC controls via Excel The second Award of Distinction in the Electronic/ spreadsheet. Electrical Category earned by Indo-US MIM Tec Pvt. Ltd, was for two parts, a male fool-proof device and a female polarizer (Fig. 8), made for Amphenol Air LB France. Made via MIM from 4340 low-alloy steel, the parts go into an electric connector assembly made for Airbus. Both parts are fabricated to net shape, with all dimensions achieved in the as-MIM condition; this includes the threads, which Heerstraßenbenden 10 Telefon: + 49 - 2226 9087 - 0 are formed through auto unwinding in the tooling. The D-53359 Rheinbach Telefax: + 49 - 2226 9087 - 10 Germany E-Mail: [email protected] fabricator delivers 320,000 pieces annually. Internet: www.inmatec-gmbh.com www.mpif.org

Carbon nanotube reinforced iron- SETTER based MMCs produced by Powder The POWDERS that KILNFURNITURE Injection Moulding

Metal Matrix Composites (MMCs) for the MMCs was prepared by first using carbon nanotubes (CNTs) mixing the iron powder with stearic make the PRODUCTS as the reinforcing material have acid at 60°C followed by the addition generated significant interest in of paraffin wax and CNTs with mixing From the global leader in P/M and MIM powders recent years through their ability to at 90°C, and finally adding HDPE and produce lightweight components mixing at 160°C. The proportions combined with high stiffness and of the various materials used to strength. Researchers at Veermata produce the PIM samples are shown Jijabai Technological Institute in in the Table. Solvent debinding was Take innovation to the next power with AMETEK, the Matunga, Mumbai, India, have preferred to thermal debinding been investigating the use of the because of more complete binder leader in powder metallurgy since 1970. Powder Injection Moulding (PIM) removal. Sintering was done in an process to produce value added inert atmosphere at 1150°C for 2 hr Whether you’re producing components for automotive, MMC products with iron powder which was found to be sufficient to derived from grinding waste as provide bonding between the iron and aerospace, medical, marine or lock hardware applications, the base metal. On its own this CNTs. AMETEK Motor Vehicle Series, P/M Stainless, MIM, type of iron powder would have Some porosity was found in Ultra Stainless and Titanium powders can be custom inadequate properties but when the sintered PIM samples, but CNTs are added significantly the researchers state that work is formulated to your exact specifications. better properties can be achieved. underway to improve sintered density V.J. Pillewan and co-researchers and hence to improve strength Regardless of the volume and properties you require, published their findings on the use properties. As the percentage of AMETEK has the ideal solution. Using proprietary of PIM to produce Fe-CNT MMCs CNTs increases in the samples it LOW WEIGHT in the International Journal of improves the hardness of the Fe-CNT methods for manufacturing superfine metal powders GOOD MECHANICAL STABILITY Emerging Technology and Advanced composite. However, adding more and roll-compacted powder, there’s a formulation LOW HEAT CAPACITY Engineering (Vol. 5, No. 5, May CNTs may leading to fracture of these that’s right for you. HIGH OPEN POROSITY 2015). samples, and further optimisation DUST- AND PARTICLE-FREE SURFACE They stated that carbon is required. Hardness values ranged HOMOGENEOUS SHRINKAGE nanotubes were added to iron from 55 to 87 HRB. Wear tests on the Our powder allows you to provide innovative products powder in fractions ranging from PIM Fe-CNT MMCs are reported. that add value to your existing capabilities, help you 1% to 6% by weight. The feedstock FOR THE SINTERING develop new markets, and meet your customers’

Absorbtion of the binder into the pores Iron powder 85% 75 g 75 g 75 g 75 g during the | Very debindering process CNT 0.9 g (1%) 2.65 g (3%) 4.41 g (5%) 5.29 g (6%) smooth surface Finish | Compatibility to Molybdenum, CFC, RSiC | Good to very Binder good thermal shock resistance| Hand- Innovative & Advanced Metallurgical Technology ling and assembly with robots possible. Paraffin wax (70%) 8.65 g 7.41 g 6.18 g 5.56 g

HDPE (12%) 1.48 g 1.27 g 1.06 g 0.96 g P.O. Box 427 • Route 519 Depending on the application, you can Eighty Four, PA 15330 USA choose between our Keralpor 99 | Ke- Stearic acid (18%) 2.22 g 1.91 g 1.59 g 1.43 g ralpor S | RT or Keralpor select 99 Z. Tel: +1 724-250-5182 • Fax: +1 724-225-6622 Total 88.25 g 88.24 g 88.24 g 88.24 g Email: [email protected] Table 1 Mixing of proportions of Fe-CNT MMCs (From paper by V.J. Pillewan, www.ametekmetals.com VISIT OUR BOOTH NO A2.206 AT et al. published in the International Journal of Emerging Technology and THE CERAMITEC 2015 IN MUNICH Advanced Engineering (Vol. 5, No. 5, May 2015)

Tel.: +49 (0) 96 45 - 88 300 [email protected]

www.kerafol.com 9001:2008 CERTIFIED

Expansion of powder production operations at Atomising Systems your system provider for the additive manufacturing Atomising Systems Ltd, Sheffield, UK, has reported that it has expanded its workforce to cope with a major influx of high-performance ceramics of orders for metal powder. Staff numbers at its Darnall facility have increased from 35 in September 2014 to over 60 in June 2015 to allow the company’s two 500 kW melting furnaces to operate at maximum output to service an order book stretching into 2016. The company, which as well as manufacturing metal powders is a major supplier of equipment for the atomisation of metals, has taken on four new apprentices to join several that were hired two years ago and who are now finishing their training. As well as hiring enough staff to operate the existing plant at maximum output, ASL is investing heavily in new equipment. A £100,000 major upgrade of the gas atomiser is in hand, while a large new sieving station of similar cost has just been put into production on special steel grades. Further investments include a new instrument using laser diffraction to measure particle sizes as fine as one micron and the QC laboratory is being expanded with the addition of an oxygen analysing system. Simon Dunkley, who took over management of the company from his father, Dr John Dunkley, in 2010 stated, “After some tough times, it is very gratifying to see our investment in plant and research at last paying dividends. CERAMITEC 2015 It is particularly pleasing to be able to offer so many young MUNICH people the opportunity to work in a leading-edge technical 20 environment that allows so much scope for them to - 23 OCTOBER develop their talents. Our recent investments should – further allow us to fulfil the exacting demands of leading HALL B1 BOOTH 330 metal powder users around the world.” www.atomising.co.uk

HIGH-PERFORMANCE CERAMICS PROTOTYPES. SMALL SCALE SERIES. HIGHLY COMPLEX PARTS.

production & sales of machines and materials

customer-specific developments & individual solutions

consulting & assistance by our in-house specialists The company’s new apprentices with Simon Dunkley (centre). Left to right: Ashley Coe, Steven Parker, Natalie Galt and Ben Twomey www.lithoz.com

Engel signs exclusive ATI expand nickel based EURO PM2015 Technical Liquidmetal agreement superalloy powder capability Programme now available

Injection moulding machine producer Engel Holding Allegheny Technologies Incorporated (ATI) is investing The Euro PM2015 Congress & Exhibition Technical GmbH, Schertberg, Austria, has signed an agreement with around $70 million to expand its nickel-based superalloy Programme, including papers, tour information and Liquidmetal Technologies Inc., Rancho Santa Margarita, powder production to satisfy strong demand from the exhibitor listing is now available from the European California, USA, whereby Engel will be the exclusive aerospace jet engine market. The development is expected Powder Metallurgy Association (EPMA). The annual machine manufacturing partner for Liquidmetals’ to take two years to complete and will be located at its Powder Metallurgy event will this year be held in Reims, unique patented process for producing components from Specialty Materials business unit in North Carolina, USA. France, October 4 - 7, 2015. Euro PM2015 will cover all the amorphous alloys by Liquidmetal injection moulding. Nickel-based superalloy powders provide extreme aspects of Powder Metallurgy including: The exclusive agreement was announced at the 2015 alloy compositions and a refined microstructure that • Additive Manufacturing Engel Symposium held in St Valentin, Austria, June 16-18, offer increased performance and longer useful lives in • Hard Materials and Diamond Tools where a special all-electric E-Motion injection moulding high-temperature and highly corrosive environments. • Hot Isostatic Pressing production cell (Fig. 1) was demonstrated for Liquidmetal Fig. 1 Engel’s special Liquidmetal all-electric E-Motion “This strategic growth project will strengthen ATI’s position • New Materials and Applications injection moulded medical forceps (Fig. 2) from an injection moulding machine in the production of technically demanding superalloy amorphous alloy based on zirconium. powders used to produce advanced mill products and • Powder Injection Moulding The amorphous alloys are available in the form of slugs can, for example, be removed with the help of a forgings, primarily for next-generation jet engines,” stated • PM Structural Parts cut from round rods. These slugs are automatically fed water-jet cutting machine or mechanical shears. Rich Harshman, ATI’s Chairman, President and CEO. There are also a number of Special Interest Seminars into a melting chamber where the material is induction Dr Gerhard Dimmler, Engel Vice-President Research “A significant portion of the powders to be produced with invited papers focused on: melted under high vacuum. Instead of a screw normally & Development Products, stated these amorphous from this expansion are needed to meet requirements of • Status and Trends in Additive Manufacturing used in injection moulding, the special Engel machine has materials are extremely hard, but at the same time existing long-term agreements with jet engine OEMs that • State-of-the-art on Fast Sintering Processes for Hard a piston with which the molten metal alloy is injected into highly elastic, with an elasticity of 2%, compared to 0.2% run well into the next decade. The expansion also better Materials a thermo-regulated mould. Very rapid cooling leads to the for steel and 1% for titanium. Liquidmetal amorphous positions ATI to continue as a leading innovator supplying formation of the amorphous structure in the zirconium zirconium alloys also have a low specific weight and advanced powders to the new and rapidly growing Additive • Key Issues in Sintering alloy which gives the material its unique characteristics. excellent corrosion resistance, which make these Manufacturing industry,” added Harshman. www.europm2015.com Robots are used to remove the finished parts. The sprue alloys particularly suitable for moulding precision www.atimetals.com components. Additionally, the shrinkage rate during rapid solidification is extremely low (0.4%) which allows injection moulding to net shape. Engel sees good potential for components produced by Liquidmetal injection moulding in the field of Full-Mould Binders and Feedstocks medical technology, with the parts for the forceps being moulded at the Symposium being a good example, Thermal only & single-step de-binding + sintering system while endoprostheses such as hip joints or stents are also conceivable. Thanks to the excellent mechanical Best combina5on of ﬂowability and viscosity for excellent injec5on quality properties of the material, very robust components can High expansion in the mold by barus eﬀect for excellent transferability also be achieved with very low wall thicknesses. Minimize binder residue by thermal only complete decomposi5on www.engelglobal.com | www.liquidmetal.com Extraordinary shape retaining rigidity elimina5ng secondary sizing

Item MFR (g/10min) Viscosity Density (g/cc) TG50% (℃) TG100% (℃)

M1 106.43 1.80 0.9655 382 510 M3 42.16 1.84 0.9677 398 510 M4 256.81 3.74 0.9588 378 510 C1 645.72 1.43 0.9833 346 510 C7 244.98 1.34 0.9924 335 510 CS13 1024.23 1.29 0.9190 367 510

M1 : Improves deforma5on and cosme5c rejec5ons M3 : Minimize impurity residue and porosity for perfect surface Fig. 2 Parts for medical forceps were produced from a www.atect.co.jp e-‐mail : [email protected] Liquidmetal alloy at the 2015 Engel Symposium held in atect St Valentin, Austria

in MIM production. Stainless steels remain by far the Japanese MIM production largest group at 62.2% followed by Fe-Ni base alloy, and Ceramic Injection Moulding data shows further decline magnetic materials at 8.7%. and gas-pressure sintering in sales www.jpma.gr.jp used to process ultra-fine Plasma Atomized silicon nitride powder The Japan Powder Metallurgy Association (JPMA) recently Spherical Metal Powders published a market report which showed that sales of Sales of MIM Products in Japan Metal Injection Moulded products declined for the fifth 16000 Silicon nitride (Si3N4) ceramics have been produced 13891 14000 by a number of manufacturing processes for use as Designed specifically successive year in 2014 (Fig. 1). Sales of Yen 10.566 billion 11952 11625 11485 12000 10951 11234 11160 10745 10566 bearings, gas turbine components, and other high

($84.3 million) were recorded in 2014, an 11.6% fall on 10000 for Additive Manufacturing, MIM, sales for 2010, and a 34% drop on sales of Yen 13.981 8000 temperature environment applications. Compared with

(MillionYen) 6000 other oxide ceramics such as Al O and ZrO , Si N billion achieved in 2008. 2 3 2 3 4 CIP/HIP & Coating processes. The JPMA figures were based on the returns of 21 4000 is less dense and exhibits lower thermal expansion 2000 companies in Japan active in Metal Injection Moulding co-efficient, a greater strength retention at high 0 production. The JPMA is forecasting a small recovery 2008 2009 2010 2011 2012 2013 2014 2015 2016 temperature, and good corrosion resistance. in MIM sales in 2015 and 2016. MIM producers believe Yian-Feng Yang and colleagues at the Changsa Products University of Science & Technology, Changsa, and that more efforts are needed to promote the benefits Fig. 1 Sales of MIM Products in Japan (FY2008-2014: Tsinghua University in Beijing, have been investigating Titanium Grade 1 of the technology particularly in terms of quality and results, FY2015-2016: estimate) (Courtesy JPMA) dimensional accuracy of complex MIM components. the use of Ceramic Injection Moulding (CIM) to produce Titanium Alloys Ti-6Al-4V 5 & 23 The JPMA reports that the main application sectors for high precision and complex functional shapes having MIM parts in Japan remain industrial machinery at 23.6% high surface quality from ultra-fine Si3N4 powder. Nickel Super Alloys Markets for MIM products in Japan, FY2014 (20.5% in 2013), followed by medical instruments at 18.3%, The authors report the results of their investigation Niobium and automotive at 17.3% - down from 19.3% in 2013. Fig. Industrial Machine in the International Journal of Minerals, Metallurgy Industrial Robot Others 23.6% And Other High Melting Point Metals 2 gives a breakdown of all the application sectors for 1.5% 12% and Materials (Vol. 22, No. 6, June 2015). They state Information MIM and Fig. 3 gives a breakdown of the materials used Equipment that although CIM is successfully used for some oxide 11.2% ceramics, it has not yet been extensively used for Si N 3 4 Features Motorcycle because of the difficulty in producing a CIM feedstock 3.8 % with a sufficiently high powder loading and low viscosity. • High purity Watch This is especially the case for sub-micron Si N powders. 4.2% 3 4 • Excellent flowability Automotive The researchers used Si3N4 powder having a median Key or Lock System 17.3% 4.1% particle size (d50) of 0.34 micron where the α-Si3N4 • Few satellites Camera & Precision Communication Machine 1.4% Equipment phase content was greater than 92 wt%. This was ball 2.6% Medical Appliance • Highly spherical 18.3% milled in ethanol together with a sintering additive (6

wt% Y2O3 + 2 wt% La2O3) and the resulting composite • Low oxygen content Fig. 2 Distribution ratio of MIM markets in Japan slurry was dried for use in the CIM feedstock. The • High apparent and tap densities (FY2014) (Courtesy JPMA) organic binders used for the feedstock included polypropylene (PP), polyethylene (PE) and wax (PP:PE:W = 10:10:80 by mass). Additionally, stearic acid was used Usage of MIM materials in Japan, FY2014 as a surfactant. Spherical parts and test bars were produced from the feedstock by injection moulding followed by solvent debinding at 40°C, thermal debinding Stainless Steel 62.2% at 900°C, and gas pressure sintering at 1795°C for 3 hrs Others, 6.3% under N2 pressure of 8 MPa.

Ti Alloy The results show that a solid loading of less than 1.6% 50vol% and the surfactant mass fraction of 6wt% gave Tool Steel 22 perfect flowability of the Si3N4 feedstock making it 2.6% suitable for CIM. Defects detected during production Ti47.867 Heavy Alloy Titanium 3.6% Magnetic Materials are traced to improper moulding parameters, mould 8.7% Fe-Ni base Alloy design, debinding parameters, residual stress, or Low Alloy Steel 10.7% 4.3% inhomogeneous composition distribution in the green www.advancedpowders.com parts.Gas pressure sintered properties of Si N included Fig. 3 Distribution ratio of MIM materials in Japan 3 4 density of 3.2 g/cm3, Vickers hardness of 16.5 GPa, and [email protected] (FY2014) (Courtesy JPMA) fracture toughness of 7.2 MPa.m1/2. Tel: +1 450.434.1004 www.csust.edu.cn

ISO 9001 : 2008 / AS 9100C

debinding has the potential to be cost temperature to 60°C followed by PSI Limited University Carlos III studies PIM of efficient for PIM production of ZrSiO4 thermal debinding at up to 500°C, and zirconium silicate components. This binder system is sintering at 1500°C for 3 hr. The PIM Advanced Process also eco-friendly through the use of a processed ZrSiO4 parts were found Solutions high percentage of soluble polymers to be defect free. The sintered parts A recently completed ECOPIM 93-100) by authors Carolina Abayo, A. and CAB which brings about zero were tested for dimensional change, research project undertaken by the Jimenez-Morales, and J. M. Torralba. balance of CO2 emissions through its relative density by water absorp- University Carlos III de Madrid in The authors stated the raw ZrSiO4 Stand thermal degradation. tion method and flexural strength 55 collaboration with Spanish partners powder, grade ARMIN-05 supplied by To fully test the B3 binder system, obtained on a three-point bending Guzman Global, based in Nules, Guzman Global, was obtained from green parts having dimensions testing machine. A competitive and MIM-Tech Alfa, based in Eibar, mineral sands zircon silicate. The of 60 mm x 8 mm x 4 mm were flexural strength was reported for the has resulted in a new Powder powder had a particle size distribu- injection moulded. Water solvent sintered PIM ZrSiO test pieces. Fig. 1 Morphology of raw zircon 4 Injection Moulding processing tion of 1.94 µm (D50) and 5.49 µm debinding was carried out from room www.uc3m.es route to produce components from (D90) respectively; apparent density powders obtained by SEM (From We make the

zirconium silicate (ZrSiO4). is 19.05%. The irregular morphology paper by C. Abajoa, etal.Boletin de CAB CAB PEG PEG PEG PEG The new process developed (Fig. 1) of the ZrSiO powder contrasts la Sociedad Espanola de Ceramica y SA PTZ systems ... 4 30K 20K 20K 10K 4K 1.5K under the ECOPIM project is said with the normally spherical powder Vidrio, June 2015) to use a feedstock binder system morphology used in Powder Injection B1 30 70 with a high percentage of soluble Moulding. They studied PIM binder on the PIM process; PEG between B2 30 33.5 33.5 2.5 0.5 polymer which is more eco-friendly systems composed of Cellulose 1.5 K and 20 K Mw and CAB between than conventional binders. The Acetate Butyrate (CAB), which is an 20 K and 30 K Mw. It was stated that B3 30 33.5 33.5 2.5 0.5 results of the project, which had the alternative to polyolefin, and Polyeth- optimising binder system design is B4 30 33.5 33.5 2.5 0.5 objective of finding new applications ylene Glycol (PEG), a water-soluble extremely important to avoid defects for zircon silicate in sectors such as polymer, to which was added stearic in the PIM parts at different produc- B5 30 33.5 33.5 2.5 0.5 ... that make tion stages. It was established that a automotive, aerospace, jewellery, acid as surfactant and antioxidant B6 30 50 5 5 10 telecommunications and machinery, phenothiazine. binder system based on high-Mw of the powders ... were published in Boletin de la Different grades of molecular CAB and low-Mw of PEG (binder B3 B7 40 60 Sociedad Española de Cerámica weights (Mw) were used to study in Table 1) with a suitable rheological Table 1 Binder compositions in vol% of the binder with different grades of Y Vidrio (Vol. 54, June 2015, pp the influence of binder composition behaviour and successful solvent molecular weights (From paper by C. Abajoa, etal.Boletin de la Sociedad Espanola de Ceramica y Vidrio, June 2015)

POWDERMET2016 Call for Papers issued BOOTH #24 The Metal Powder Industries Federa- • Powder Injection Moulding tion (MPIF) has issued a Call for (Metals & Ceramics) ... that make Papers for its POWDERMET2016 • Pre-Sintering & Sintering International Conference on Powder • Secondary Operations the headlines Metallurgy and Particulate Materials, • Materials Boston, Massachusetts, USA, June 5–8, 2016. • Refractory Metals, Carbides & Ceramics Authors are requested to submit abstracts for papers to be presented • Advanced Particulate Materials & in the general technical sessions Processes and poster programmes no later • Material Properties than September 18, 2015. Abstracts • Test & Evaluation can address all aspects of Powder • Applications Metallurgy and particulate materials • Management Issues technology. The technical sessions will include the following categories: The MPIF’s Additive Manufacturing • Design & Modelling of PM Mate- with Powder Metallurgy conference rials, Components & Processes (AMPM2016) will be held in conjunc- PSI Limited - Apex Business Park • Particulate Production tion with POWDERMET2016. www.powdermet2016.org Hailsham - East Sussex - BN27 3JU - UK • General Compaction & Forming Tel: +44 (0)1323 449001 Processes [email protected] - www.psiltd.co.uk

Laboratory/ Carpenter on course to PM Review: Autumn/Fall 2015 Profits increase at GKN’s PM Production Z Blade supply aerospace superalloy issue out now division Mixers powder market The latest issue of PM Review, the UK-based GKN plc has reported a solid performance in Carpenter Technology has stated that it remains confident magazine for the PM industry, has its half-year sales figures ending 30 June 2015. Overall options available that operations will begin soon at its new superalloy just been published and is available six-month sales were reported as £3,853 million, up 1% Extruder powder facility in Alabama, USA, as part of a multi-level to download free of charge from on the same period in 2014. GKN’s Powder Metallurgy agreement with United Technologies Corporation’s (UTC) www.ipmd.net. division, which comprises GKN Sinter Metals and metal Pratt & Whitney Division. The agreement with UTC was This 84 page issue features the powder producer Hoeganaes, achieved first half organic signed in October 2013 and includes Carpenter supplying following articles and technical sales of £474 million, £6 million higher (1%), after the £8 Pratt & Whitney with superalloy powder for up to 20 years. reports: million pass through to customers of lower scrap steel Gregory A Pratt, Carpenter’s Chairman, President and • An introduction to Powder prices. There was no impact from currency translation Metallurgy Soft Magnetic and there was a £3 million decline as a result of a Chief Executive Officer stated, “We’re extremely excited Mixing for Metal Injection Moulding? to produce an aerospace superalloy powder with demand components: Materials and disposal. • Winkworth Z (Sigma) blade and ZX (Sigma Extruder) volumes directly linked to the move by engine manufac- applications It was stated that good growth was achieved in North mixers used by MIM stock producers worldwide. turers to develop better fuel-efficient engines. Carpenter • Sintering in PM: Selection of sintering tray material for America, China and Europe but sales in Brazil fell due is also optimistic that demand for superalloy powder will improved part quality to weaker automotive and industrial markets. The • Easy clean chamber and blade removal versions available. begin to grow in other key markets we serve.” • POWDERMET2015: North America’s PM industry company’s PM division includes one of Europe’s largest • Sizes from 0.5 to 500 litres. Pratt added, “Our relationship with UTC has allowed continues on growth track; MPIF PM Design Excel- MIM operations, located in Bad Langensalza, Germany. • Vacuum, cored blades, oil/electric jacket, chamber size and us to expand our position as a key supplier in the fast- lence Awards 2015 The organic increase in profit was £2 million and control options. growing aerospace market. With the recent opening of • POWDERMET2015: Further developments in Hot there was a £1 million gain on currency translation. • Robust, reliable, minimal maintenance for high performance our technologically advanced lean manufacturing facility Isostatic Pressing technology The divisional trading margin was 11.8% (2014: 11.3%) and reliability. in Alabama, which is adjacent to the superalloy powder PM Review is available in both print (ISSN 2050-9693) reflecting the move towards higher value “design for For more information about Winkworth Mixers Powder Metallurgy” parts and a small margin benefit facility, our ability to supply ultra-premium products for and digital (ISSN 2050-9707) formats. Current and past Call Sales on: +44 (0)1256 305600 the aerospace market has never been better.” issues are available to download free-of-charge. from lower raw material prices passed through to E: [email protected] www.cartech.com www.ipmd.net/pmreview customers. Return on average invested capital was W: www.mixer.co.uk 22.0% (2014: 21.0%), reflecting the improvement in profitability. During the period, GKN Powder Metallurgy continued to achieve a number of important milestones, which included continuing strong product and development activities in engines and transmissions and a strengthening of its position in China following the announcement of a new joint venture to produce metal powders. The company has also developed a new range of technically enhanced titanium powders at its Powder PolyMIM GmbH is a manufacturer offering two different Innovation Centre in the US. binder systems for MIM: Commenting on the results, Nigel Stein, Chief Execu- • polyPOM – our catalytic binder system tive of GKN, stated, “This was another solid perfor- • polyMIM – our water soluble binder system mance, particularly in our automotive businesses, with GKN Driveline delivering 4% organic sales growth and These two binder systems have excellent characteristics an 8.3% trading margin while GKN Powder Metallurgy during the production process and combine attractive achieved an 11.8% margin. GKN Aerospace delivered prices with worldwide availability. in line with expectations and won some important new Our portfolio covers high-end applications with our special contracts for the future. We have continued to perform alloys as well as the mass production requirements seen well against our key markets and report good results in in the automotive and telecommunications industry, for spite of some end market weakness, particularly in GKN example. Land Systems. We expect these trends to continue in the Every possible challenge in the MIM process can be second half and for 2015 to be another year of growth. overcome with our range of products tailored to our The acquisition of Fokker Technologies, also announced customers’ requirements. Contact us to find a match for today, supports our strategy, brings excellent tech- your application! nology, an expanded geographic footprint and additional Phone: +49 6751 85769-0 Fax: +49 6751 85769-5300 content on high growth aerospace programmes.” Email: [email protected] www.gkn.com www.polymim.com

Inmatec Technologies GmbH: A feedstock supplier at the

Visit us: Hall B1, Stand 109 forefront of CIM technology

Ceramic Injection Moulding has come a long way in recent years, with the industry blossoming from the manufacture of simple engineering components to the production of advanced dental implants and beautiful watch components for the world’s most prestigious luxury brands. As Dr Georg Schlieper reveals for PIM International, behind this success are specialist feedstock producers such as Germany’s Inmatec Technologies GmbH.

FCT Anlagenbau GmbH promote, design, manufacture and sell systems for the development and production of heavy-duty material. Inmatec Technologies GmbH was manufacturer Arburg GmbH + Co KG. grew rapidly. The commercial binder founded in 1998 as a specialist There he realised that there was system used for this initial order has producer of thermoplastic ceramic a need within the PIM industry for since proven so successful in such a feedstocks. The company is located high quality feedstocks and decided wide range of applications that it is in Rheinbach, a medieval town to establish a business in this field. now commonly used in the company’s Our performance The furnace specialist for with a population of around 28,000 He started with a commercially standard PIM grades as well as in  Consulting during the conception of a plant  Vacuum  Gas pressure sintering located close to Bonn, the seat of available binder system that he customer-specific feedstocks. Today, government of the former West compounded with ceramic powder. Inmatec is the leading supplier of  Development and design of plants  Hot pressing  Debinding Germany. Situated in the middle of a The requirements of his very first thermoplastic ceramic feedstocks  Manufacturing of plants  Annealing  Tempering fertile agricultural region, the town customer, who is still a customer in Europe with customers all over has a tradition of glass manufacturing today, increased much faster than the world. In addition to his work at  Start-up and After-Sales Service  Sintering  Heat treating following the arrival of Bohemian initially planned and the company Inmatec, Dr von Witzleben is CFO of  glass manufacturers who were forced Maintenance and modernisation of existing plants to leave their homeland after World War II. Today, Rheinbach houses a sectoral campus of the Bonn-Rhein- Sieg University of Applied Sciences. Inmatec cultivates close contacts with Applications this university, as well as the Koblenz   University of Applied Science’s Maximum temperature continuous furnaces Sintering furnaces Department of Material Science in  Gas pressure sintering furnaces  Vacuum hot presses Höhr-Grenzhausen, where regular seminars are held about Ceramic  Debinding and pyrolysis furnaces  Thermal post combustion Injection Moulding technology.  Special plants and manipulating eqiupments  Solvent debinding system Founder and CEO of Inmatec Technologies is Dr Moritz von Witzleben, a mineralogist who during his PhD thesis work came in contact with the PIM group at specialist injection moulding machine Fig. 1 The home of Inmatec Technologies GmbH (Courtesy Inmatec) FCT Anlagenbau GmbH Hönbacher Str. 10 Tel. +49 3675 / 7484-0 email: [email protected] Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 43 D-96515 Sonneberg Fax +49 3675 / 7484-44 web: www.fct-anlagenbau.com Inmatec Technologies | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email | Inmatec Technologies

The company’s market share in Asia Raab, Sales and Project Manager at is still relatively small. Inmatec, “because the manufacturing Of Inmatec’s staff of 25 employees, process is more complex and each nine work in R&D and eleven work in step must be optimised separately feedstock production. Five production and in detail.” shear roll machines operate in two In recent years, the market shifts. Further, up to four students demands on the ceramic powders are supervised and guided in their have become more specific and Bachelor, Master or Diploma thesis Inmatec has reacted to these work as well as carrying out their requests with a build-up of expertise practical work at Inmatec. This in powder processing. Particle size cooperation is a win-win situation for distribution, specific surface and the students and for Inmatec. The chemical composition are the main students gain insight into the everyday characteristics of ceramic powders. work of the industry and Inmatec CIM generally uses powders with takes advantage of their work to meet particle sizes in the range between technical challenges. Inmatec also 200 and 1000 nanometres and a regularly offers two apprenticeship specific surface between 5 and 20 m² Fig. 2 Ceramic powder and binders (Courtesy Inmatec) Fig. 4 Shear roll used for feedstock homogenisation (Courtesy Inmatec) places, one in business per gram. For the control of the administration and one for a plastics shrinkage, however, these character- and rubber process technician. istics must be specified within much Seminars held by the company at the closer limits. University in Höhr-Grenzhausen aim Exceptions, however, prove the to inspire an interest in CIM amongst rule. If needed for a special applica- young students. This is regarded as tion, nano powders as well as ceramic an important activity to secure the powders with particles sizes of more availability of skilled specialists in the than 20 microns have been processed future. successfully into ceramic feedstock. Inmatec also creates special alloy Developing customised compositions by blending powders feedstocks like zirconia and alumina in various proportions. Coloured zirconia When an enquiry is received for a new feedstocks are produced by adding CIM product, the Project Manager pigments to zirconia powder. initially analyses the application and When the powder blend has been decides whether a standard feedstock determined, the next step is the can be used. If a customised selection of the most suitable binder Fig. 5 A shear roll machine at Inmatec (Courtesy Inmatec) Fig. 3 Compounded CIM feedstock (Courtesy Inmatec) feedstock has to be developed, for the designated application. Each Inmatec’s significant experience binder is made up of several compo- the German Ceramic Society (DKG) to produce this high quality is one of and close relationships with raw nents; a basic binder, a backbone of shear roll processing is to remove a way that, with each turn of the roll, and President Elect of the European Inmatec’s key assets. material suppliers are essential in binder and additives (Fig. 2). Inmatec agglomerates and coat each powder the material is transported a small Ceramic Society (ECERS) for the Inmatec’s factory is housed in selecting suitable raw materials and has a variety of binder components particle with a polymer layer so as to distance towards the other end of the period 2017-2019. a plain functional building (Fig. 1) determining if additional powder available that can influence the flow make injection possible and reduce roll, where it is cut off by a knife. This The company’s capital comes that has a production floor space processing steps are required. characteristics of the feedstock as abrasion in the injection moulding produces uniform feedstock granules from a venture capital investor of roughly 1000 m² plus additional The choice of binder composition is well as strength and ductility of the machine. Because of the fine particle that are ideal for injection moulding. in combination with private space for raw materials and feedstock equally important. A polymer that can green compact within wide limits, as size of the powder, a very strong A shear roll machine operating shareholders, including the CEO. storage. Facilities for processing both withstand the temperatures required required by injection moulding and shearing action is required to produce at Inmatec is shown in Fig. 5. On the A further strategic investor has metal and ceramic feedstocks are for plasticising, exhibits a good subsequent processing. a high quality feedstock and the total platform behind the machine, one can secured its raw material source installed, but the focus is, to a large flowability during injection moulding, The feedstock production processing time is dependent on see the pre-mix material feeder. by buying into the company, taking extent, on ceramic feedstocks. This is adheres to the powder particles and process is, of course, at the heart powder properties. When feedstock samples have advantage of Inmatec’s materials where Inmatec’s technical expertise coats them with a homogeneous layer of Inmatec’s expertise. The shear Fig. 4 shows the set of two parallel been produced and tests on Inmatec’s development capabilities. High-end is greatest. Inmatec’s ceramic is ideal. Binder removal should be fast roll machines at Inmatec have been shear rolls. Between the rolls there is in-house injection moulding facility products for the luxury products feedstocks are used not only for CIM, without damaging the shape of the modified according to the specific a small gap. The powder-binder mix, have been successful, the customer market, in which aesthetic as well but also for thermoplastic extrusion. components, environmentally friendly requirements of the Inmatec process. which is fed into the gap at one end of also tests the injection moulding as technical qualities are essential, Approximately 70% of production is and easy to handle. Powder blend and binder are first the shear rolls, sticks on one roll and performance of the feedstock at are manufactured from feedstock exported, mainly to other European “New ceramic products often mixed mechanically and then the other roll is clean. The surface of their own facility using the tooling of the highest possible purity and countries, but also to a growing require longer development cycles plasticised and homogenised by a pair the rolls is coated to avoid abrasion for the new product. Based on quality. The knowledge and expertise market in South and North America. than other materials,” stated Daniela of heated shear rolls. The objective and their profile is designed in such the feedback from the customer,

modifications of the feedstock are, general and safe profile in terms of and durability of the products, as volumes are much lower than in the if necessary, made at this stage. time and temperature settings, ramps is common, for example, in the die pressed ceramics industry. For The next step is the definition and dwell times are improved and automotive industry. The reward is cost reasons, Inmatec has to rely and optimisation of the debinding adjusted during volume production that these products, once established, on commercially available powders process. In general, debinding is for the specific ceramic component to are produced for many years in high and it modifies them according to carried out in two steps, solvent reduce the overall debinding time. volumes and secure the regular its requirements if necessary. “We and thermal debinding. Depending The sintering cycle requires utilisation of Inmatec’s production expend immense efforts to make sure on the binder composition, solvent considerations on how to place the facilities. that our processes are constant and debinding can be performed in products in the furnace. Can they reproducible,” stated Karin Hajek. water or an organic solvent such as stand alone or do they need support “A Quality Management commissioner acetone. The solvent bath is usually by a powder bed or other means? Standard feedstocks has been appointed whose exclusive heated from 25 to 60°C in order to Supports may be used to avoid Of course, such long development task it is to supervise, maintain and accelerate the diffusion processes. distortion, but then the size and shape cycles are not economically feasible improve the QM system and carry out The purpose of solvent debinding of supports have to be defined. For for every product. Inmatec, therefore, regular quality audits.” is to remove the basic binder and new powders, the sintering cycle and also offers standard feedstocks for Hajek also announced that create a network of open porosity in the final maximum temperature need the most common materials, which Inmatec will present a new binder the CIM compacts that later allows to be defined. These parameters may are held in stock and can be delivered system at this year’s Ceramitec the evaporating backbone binder to be different from the general recom- at short notice. These are listed in exhibition. Feedstocks, based on Fig. 6 Biocompatible alumina bone screws (Courtesy Kläger Spritzguss) escape during thermal debinding mendations given by the powder Table 1. All standard feedstocks this proprietary binder system, will without causing internal pressures suppliers because CIM shaped parts are designed for solvent debinding be marketed under the trade name that might destroy the parts. The need more, and different, energy in water. The optimum processing INMAFLOW. They will be character- substances in the powder. After process of a CIM parts manufacturer, time and temperatures required for input to achieve the desired final temperature is approximately ised by excellent shape retention, a feedstock processing, the weight loss the feedstock supplier is directly solvent debinding depend on the microstructure. 150-160°C and the mould should wider processing window and shorter of the feedstock is measured for a involved and must support the parts wall thickness of the parts and the Inmatec, therefore, not only be heated to 50 to 65°C. According debinding times than the standard reverse cross check of the powder- manufacturer in the analysis of the particle size of the powder. delivers the customised feedstock, to Dr Karin Hajek, Inmatec’s Sales grades available today. Technical binder ratio. Each feedstock batch is cause of trouble, beginning with the The time-temperature profile but also develops a complete set of Director, customers who have used innovation is regarded as the best way injected with reference parameters verification of its own raw materials for thermal debinding is then processing parameters from injection standard feedstocks successfully for to secure future business and the new and a standard mould to monitor and processes and continuing determined. Based on past experi- moulding to the sintered component some time show a clear preference binder system is a significant step in batch-to-batch consistency. Injection with the detailed analysis of the ence, a general profile is applied as in close cooperation with the for the standard grades. The present this direction. Since the processing of moulded parts are also retained as customer’s production. This is only a starting point, but modifications customer. This comprehensive service annual consumption of standard these feedstocks is more robust than reference samples. possible if a trusting relationship has are often required depending on the is unique in the CIM industry and grade alumina powder by Inmatec is before, more users and new applica- The standard quality assurance been established and if the customer particle size, binder content and Inmatec is convinced that this is the 30 metric tons. tions are anticipated in the future. procedure can be extended to an is truthful and provides deep insight wall thickness of the part. Daniela way to secure and extend its strong It is not easy for a feedstock entire incoming goods inspection into its processes and internal Raab stressed the point that the business position in a high-wage manufacturer to maintain consistent Quality management that is conducted for the customer at procedures. interaction between inorganic country like Germany. feedstock quality even for standard Inmatec. Each delivered product is Inmatec sees the consulting powders and organic binders must With all these steps, the grades, because of the variations in The Quality Management (QM) system accompanied by a quality certificate services that are provided to be accounted for. Heating ramps development of a new product can be the characteristics of commercial of Inmatec is certified according to with the data determined by quality customers for the development of and dwell times may differ, not only time-consuming and tedious. In some powders. Ceramic powder suppliers the ISO TS 16949 standard. This is control on the respective production new Ceramic Injection Moulded for different binder systems, but cases, it takes one and a half to two generally show little interest in currently the strictest requirement lot. “For some customised feedstocks, products as a part of its business, also for different inorganic powders. years. Then, the end user may require complying with the specific require- that qualifies for deliveries to the the shrinkage and the mould oversize which is largely independent from Moreover, having started with a further tests to ensure the reliability ments of the CIM industry since automotive industry. The ISO TS 16949 factor are specified within very close the daily production of standard standard ensures that reference limits,” stated Raab, “and we are and customised feedstocks. samples are retained after each able to reproduce the mould factor Customers are welcome at Inmatec, Ceramic Theoretical Colour Particle size d Sintering powder 50 density processing step and kept for ten years within the third decimal. We think independent of their level of and requires that all processes are that rheometer measurements are expertise or equipment for CIM INMAFEED K1008 Al O , 96% white 1.8 -2.2 µm 3.80 g/cm³ 1620°C/air 2 3 efficiently controlled and documented. not very meaningful for our purposes, production. A large amount of processing but, if a customer asks for them, we Complete beginners are advised INMAFEED K1010 Al2O3, 99.7% white 1.0 -1.5 µm 3.86 g/cm³ 1680°C/air parameter data are recorded will comply. We can perform most about the equipment required and INMAFEED K1013 Al2O3, 99.8% ivory 0.5 µm 3.94 g/cm³ 1600 -1650°C/air electronically and continuously; other tests in-house and rely on accredited trained in handling the feedstocks white / approx. 1800°C/H data are typed into the system by the laboratories for special tests.” properly. Inmatec can order the INMAFEED K1021 Al O , 99.99% 0.4 -0.6 µm 3.99 g/cm³ 2 2 3 translucent for translucent appl. operators. design and manufacture of the The most important test during tooling, if requested by the customer, INMAFEED K1009 ZrO2 3Y (Tosoh) white 0.6 µm 6.05 g/cm³ 1400 -1450°C/air Customer support the incoming inspection of powder, and has facilities for first sample

INMAFEED K1012 ZrO2 3Y (Tosoh) white 0.6 µm 6.05 g/cm³ 1500°C/air according to Daniela Raab, is the The relationship between a feedstock manufacturing, but the regular weight loss of the powders by supplier and the consumer is much production of CIM parts is not INMAFEED K1015 ZrO2 3Y (Tosoh) black 0.4 µm 6.00 g/cm³ 1400 -1500°C/air annealing in air at 1025°C, according closer than between a parts producer considered by Inmatec because it

INMAFEED K1016 ZrO2 3Y (DK) black 0.5 - 0,7 µm 5.90 g/cm³ 1400°C/air to ISO 26845. The weight loss and their customer. If a quality would interfere with the interests of determines the content of organic problem arises in the production its customers. Table 1 Standard feedstock grades offered by Inmatec

five national research projects are Salt and pepper mills under way with the participation of Salt and pepper mills are equipped Inmatec. with grinders of fairly complex design. Fig. 8 shows examples of this product in the green (left), Engineering ceramics on brown (middle) and sintered (right) the rise states. These components were initially developed as MIM products. Numerous examples of innovative However, these are now partially CIM applications demonstrate being replaced by ceramic parts. the growing demand for complex products made of engineering Coffee machines ceramics. Many modern household coffee machines use coffee pods whose Medical applications aluminium capsules are pierced Ceramics are increasingly used in with a ceramic needle (Fig. 9). The medical technology for implants. Fig. 7 A CIM functional ceramic heating element for the inset cordless glue gun alumina part is resistant to wear Fig. 9 Ceramic Injection Moulded coffee pod needle (Courtesy Kläger An example of ceramic screws (Courtesy Steinel) and abrasion, stays sharp and does Spritzguss) used for fixing implants to the not corrode which is of particular bone is shown in Fig. 6. The screws importance in food and beverage combine high mechanical strength processing. and durability with biocompatibility. Other applications of CIM products Translucent dental brackets in medical technology are tools for An example of a translucent alumina micro-invasive surgery. Currently, product, namely dental brackets, one of the most widely used is shown in Fig. 10. These brackets materials for structural applications are almost invisible and therefore in medical technology is alumina. In aesthetically much more attractive the future, many more applications than metal brackets. for functional ceramics are expected in medical technology for innovative methods of surgical intervention, Opportunities and medical diagnostics, therapy and obstacles for CIM growth patient monitoring. Karin Hajek outlined the business Fig. 8 Salt and pepper mill grinders (Courtesy Inmatec) Battery powdered glue guns opportunities of CIM technology Fig. 10 Dental brackets made from translucent alumina (Courtesy Inmatec) Consumer product manufacturers and obstacles to a faster growth can also take advantage of ceramic from the perspective of a ceramic Research & development Research is very much a third products, as shown in Fig. 7. feedstock supplier. She regretted combined with corrosion and high Most ceramic materials are business area for Inmatec. For The first glue gun powered by a that many design engineers are temperature resistance. They are difficult to machine due to their Product development is strictly all research projects relating rechargeable battery was made not yet fully aware of the numerous electrically isolating, biocompatible high hardness. Ceramic Injection customer-oriented. Based on to the development of ceramic possible with a heating element advantages of engineering ceramics and resist most chemicals. However, Moulding, however, allows the customer enquiries, special mate- products with complex shapes by made of a functional PTC ceramic. and, therefore, do not exploit CIM the world of engineering ceramics production of complex ceramic rials, feedstocks, tools and processes injection moulding, co-injection The initial design is shown here technology as much as they could. is indeed much more diverse than components, not only from standard are developed for new applications. moulding, extrusion or other new which has a base diameter of The misconception of ceramic the average engineer with a general ceramic materials, but also from Trends in product development shaping technologies, Inmatec 10 mm, an opening of 3 mm materials, as being brittle like glass interest in materials science would functional ceramics. CIM, as a net are both the miniaturisation of is often the first port of call for diameter and a wall thickness and therefore posing an incalculable imagine. In addition to the most shape technology, offers almost 100% mechanical systems and the manu- ceramic feedstock. “We can only of 1 mm. The wall thickness has risk in structural applications, has widely known structural ceramics, raw material utilisation and can help facture of larger CIM components. support our customer’s new since been reduced. This element been disproven many times, but is such as alumina, zirconia, silicon to reduce the amount of machining New products made from functional developments successfully if we heats extremely quickly and still present in the minds of many carbide, silicon nitride and boron dramatically. Many complex shapes ceramics are also under development. ourselves are at the forefront of CIM reduces power consumption by engineers. “Ceramic materials nitride, there is a wide variety of are only viable with CIM technology. Inmatec has also significant technology development,” stated 90%. Ceramic Injection Moulding cover a wide range of properties,” functional ceramics with special “This potential,” stated Hajek, “is not activities in relation to long-term CIM Karin Hajek. “This is not limited technology enabled the production she stated, “and CIM has proven to properties for high-tech applications. fully recognised by major end-users research. This is mainly done through to the raw materials aspect of the of an element with minimal wall be a cost-efficient mass production These include piezo ceramics and of these materials who continue to cooperation in national and inter- process, but also includes a full thickness. More innovative ceramic technology that can be used to materials that change their electrical design only for simple shapes such national research projects. Inmatec understanding of, for example, applications in consumer products process almost any ceramic powder.” resistivity and other properties with as platelets or rods, although a more qualifies for such projects as an SME, advanced tooling, debinding and have the potential to contribute to Standard ceramics are temperature, the so-called positive complex design with other shapes which is at the very start of the CIM sintering technologies.” Currently a significant reduction in energy characterised by extremely high and negative temperature coefficient would be technically advantageous process chain. one international EU project and consumption by households. hardness and wear resistance, ceramics (PTCs and NTCs). and commercially attractive.”

48 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 49 Inmatec Technologies | contents page | news | events | advertisers’ index | email |

Future trends

The diversity of ceramic materials, covering a broad range of properties International exhibition and conference and novel processing technologies for complex shapes that could on additive technologies and tool making not be imagined before, opens vast opportunities for the future. Functional ceramics are expected to find significantly more applications in the next five to ten years. The development of new products will be accompanied by steadily growing demands on ceramic powders with tighter technical specifications. Integrating two or more different Frankfurt am Main, 17–20 November 2015 materials in one product by multi- formnext.com component injection moulding, or the combination of extrusion and injection moulding, will become standard Fig. 11 CIM zirconia watch parts for the luxury market (Courtesy Inmatec) processes. Additive Manufacturing Innovations. is just beginning to be used on an industrial scale and its future Besides exhibiting at the contaminate the feedstock. This potential can hardly be estimated forthcoming Ceramitec exhibition can result in undesired dark spots currently. Impulses. in Munich, Germany, from on aesthetic parts, which leads to According to Karin Hajek, ceramics October 20-23, which is considered rejection. Inmatec has therefore can provide a significant contribution as the most important event for modified all of its equipment so that to meeting the challenges of Inspiration. the European ceramics industry, contact of the ceramic powder and the growing world population, networking in professional feedstock with metal is minimised. environmental pollution, global organisations is another important Karin Hajek stated, “We have made warming and demographic change in The world’s leading companies in additive manufacturing technologies source of new projects. Germany’s great progress in reducing the industrialised countries. “Not only is and highly specialized tool-making will show you their expertise at formnext DKG trade association, Europe’s reject rates of aesthetic ceramics CIM a raw material and energy saving ECERS and the German language produced by our customers with powered by tct. manufacturing technology itself, MIM and CIM Expert Groups are our feedstocks and are still working but CIM products with their unique Discover how additive technologies can be intelligently combined with highly valued as places where on further improvement. Today, combination of properties are also Inmatec can meet and network with Inmatec probably delivers the conventional procedures in product development and production, and how suitable for technical innovation that materials and equipment suppliers, whitest zirconia feedstock in the helps solve many of the challenges of you can use innovative processes to reduce your time to market even further. research organisations and parts industry.” our time,” she concluded. manufacturers. Such groups enable New potential across the entire manufacturing process is waiting to be a pooling of resources to move CIM Translucent ceramics discovered by you. We are looking forward to seeing you! technology forward, as a company Translucent alumina is at least Contacts such as Inmatec does not, by as demanding on feedstock purity itself, have sufficient resources for as white zirconia. The feedstock Inmatec Technologies GmbH widespread technology marketing for translucent alumina is made Dr Karin Hajek Where ideas take shape. activities. from ultra-pure alumina powder Dipl.-Ing. Daniela Raab of minimum 99.99% purity and an Heerstrassenbenden 10 Aesthetic ceramics average particle size D50 of 0.4 D-53359 Rheinbach, Germany The focus of Inmatec is, instead, on µm. The entire processing route Tel: +49 2226 9087 41 further improving feedstock quality must be strictly controlled so that [email protected] and technical innovation. Aesthetic any contamination with metallic [email protected] ceramics, with white zirconia leading particles is absolutely prevented. Get your free the way, are of significant interest The sintered products must be Author ticket here: in this respect (Fig. 11). Since the free of porosity and the grain formnext.com/tickets ceramic powder and binder inevitably size should be smaller than the Dr Georg Schlieper come into contact with metallic wavelength of visible light, i.e. 400 Gammatec Engineering GmbH components in the compounding nanometres. When these conditions Mermbacher Strasse 28 process, the chances are that are met, alumina can be almost as D-42477 Radevormwald, Germany Information: abrasion of metal particles will transparent as glass. [email protected] +49 711 61946-825 Follow us on @ formnext_expo [email protected] Social Media # formnext15

Connecting Global Competence Ceramic Injection Moulding adds to the allure of luxury watches

Recent years have seen an increasing number of leading luxury watchmakers embracing Ceramic Injection Moulding (CIM) for watchcases, bezels, bracelet segments and even movement parts, adding a significant premium to their already successful metal based timepieces. The development and application of new types of ceramic powders, binders, and processing equipment for CIM watch components has also added to the sector’s success. Bernard Williams, Consulting Editor of PIM International, reports on recent CIM applications from the luxury market.

Ceramic Injection Moulded zirconium and boron carbide, have also been parts can be polished to give a satin

oxide (ZrO2) was first developed for introduced. The ceramic powders are or gloss finish. luxury watchcases and bracelet blended with a binder, homogenised The chemically derived ultrafine

segments in the mid-1980s by Rado and granulated to produce the ZrO2 powder, first produced Watches of Lengnau, Switzerland CIM feedstock. Following injection commercially by Tosoh Corporation (today part of the Swatch Group) and moulding, the components go through in Japan in 1983, shows very good IWC Schaffhausen, also based in binder removal stages and are sintering activity and, with appropriate Switzerland. The work that went into then sintered in dedicated sintering powder processing, it can be readily The perfect recipe for success. developing ceramic watches paved furnaces. After sintering, the CIM sintered to practically theoretical the way for the introduction of the first series CIM production models ceramitec 2015 is the sureﬁ re way to give your busi- for IWC and Rado in 1994. IWC ness the competitive edge. Exhibit at this leading introduced the Da Vinci, said to be the international exhibition and enjoy the beneﬁ ts of a most complicated wristwatch ever truly professional forum: produced in ceramic at that time, and ∙ Full coverage of the ceramics sector. Rado introduced the Integral. Since then the luxury watch High-caliber trade audience from around the world. ∙ industry has fully embraced all that ∙ Professional services for exhibitors. Ceramic Injection Moulding has Don’t delay. Sign up today! to offer, whilst, at the same time, making significant technical advances To register: in terms of quality, performance and www.ceramitec.de/application the diversity of surface finishes and colours that can be achieved. CIM watch components are, in the main, produced using ultrafine tetragonal zirconia powders although other types of ceramic powders such Fig. 1 IWC Schaffhausen’s Da Vinci Chronograph Ceramic uses a combination as silicon nitride, titanium nitride of high-tech ceramic zirconium oxide and titanium (Photo IWC Schaffhausen)

IWC Schaffhausen IWC Schaffhausen has, over the past twenty years, significantly expanded its range of ceramic watch cases and bracelet parts. The latest Da Vinci ceramic watch is housed in a distinc- tive 44 mm wide tonneau-shaped case (Fig. 1). IWC Schaffhausen also uses CIM cases for the Ingenieur Constant Force Tourbillion (Fig. 2), the Ingenieur AMG and the top-of-the- range Luminor 1950 brands. Recently, a novel brown ceramic watch case was introduced for IWC Schaffhausen’s special limited edition Pilot’s Watch Chronograph Antoine de Saint-Exupery (Fig. 3). Here the watch case is made from a mixture of silicon nitride and titanium nitride powders Fig. 2 IWC Schaffhausen’s Ingenieur Fig. 3 Brown ceramics used by IWC Schaffhausen for its Pilot’s watch with the material sintered at 1800°C Constant Force Tourbillon combining Chronograph Antoine de Saint-Exupery (Photo IWC Schaffhausen) in a nitrogen inert gas atmosphere, platinum and ceramics (Photo IWC using overpressure during sintering Fig. 4 The Integral was the first Rado Fig. 5 The Rado HyperChrome XXL Schaffhausen) to attain full density. The combination ceramic watch to be produced in Chronograph uses plasma surface of the two ceramic materials is said to series (Photo Rado Watch Co. Ltd.) treatment to achieve the platinum density. The sintered material exhibits times, thermal debinding and water specialising in producing parts make the silicon nitride even harder colour effect on ceramics (Photo Rado an unusual combination of several or solvent debinding are also used. for watches. The company states and more shatterproof than most Watch Co. Ltd.) favourable properties; it shows The solvent debinding process has that these new furnaces offer other ceramics, but its increased high strength, high toughness, high been widely adopted in the CIM sector manufacturers the flexibility to use hardness does require more effort in hardness, low thermal conductivity, in recent years where a portion of the various types of feedstock systems, subsequent finishing steps such as a high volumetric density and a high binder is chemically removed using making it easier to test and use new grinding and polishing. refractive index [1]. The high strength solvents such as acetone, trichloro- CIM feedstocks without having to of sintered zirconia is said to be ethane, heptane and even water. The invest in a new debinding furnace [2]. Rado associated with the very fine crystal- open porosity created in the ceramic Black zirconia parts have become Since Rado released its first mass- standard for many CIM watches. produced ceramic watch, the Integral, “The sintered material exhibits an However, a number of higher end in 1994 (Fig. 4) Ceramic Injection watch producers are turning their Moulding has become a proprietary unusual combination of several attention to incorporating other feature of all Rado watches. In addi- colours such as red, blue, orange, tion to featuring the inaugural black favourable properties; it shows white, grey, brown etc. For coloured zirconia, the company now includes high strength, high toughness, high CIM zirconia parts, the material ceramic watches in pink, turquoise, has to be pigmented, with pigments burgundy, blue, purple and metallic hardness, low thermal conductivity, being mixtures of several transition colours. Surface treatment can give metal oxides such as iron, cobalt, the ceramic material a metallic a high volumetric density and a high nickel, manganese and chromium. brilliance or particular colour such as The key to the selection of colouring platinum. Fig. 6 Rado’s Esenza Ceramic Touch is controlled by the press and sweep of a refractive index” pigments is that they must survive To achieve this, Rado has finger alongside of the case (Photo Rado Watch Co. Ltd.) the high sintering temperature developed and patented a plasma lite size of the sintered material, component after solvent debinding without evaporating or melting carburising process where gases usually not more than 0.3 - 0.5 µm, allows the degraded binder products activated at 20,000°C alter the surface watch with touch functions. The Rado In 2015, Rado turned to brown allowing a four-point bend strength of to diffuse easily to the surface of the composition and surface colour of the Esenza Ceramic Touch (Fig. 6) is for its new range of HyperChrome 1000 MPa or more. parts. Recent and noteworthy CIM ceramic without affecting its essential controlled by the touch and sweep of timepieces. The company uses both Significant progress has been LÖMI of Aschaffenburg, Germany, watch developments properties such as scratch resistance. a finger alongside the ceramic case, polished and matt chocolate brown made in debinding technology for an equipment manufacturer The result is a striking metallic left for hours and right for minutes. coloured ceramic for the cases and ceramic watch parts in recent years. specialising in solvent debinding, This review highlights just a few brilliance without the use of any metal Another application of CIM at Rado bracelet parts using Ceramic Injection In addition to the catalytic debinding states that it has seen a significant recent developments by various (Fig. 5). is the Diamaster Skeleton with black Moulded ultralight silicon nitride approach developed by BASF, which increase in demand for its solvent manufacturers that illustrate In 2014, Rado introduced a world ceramic case and strap which has (Fig. 7). For the Limited Edition Rado shows excellent performance in debinding furnaces over the past few the state of the art in CIM watch first to the watchmaking world, a been produced in a limited edition of HyperChrome Automatic Chrono- terms of extremely short debinding years including CIM manufacturers applications. high tech injection moulded ceramic just 499 pieces. graph Tachymeter, the company’s

Fig. 7 Rado turned to silicon nitride for Fig. 8 A world first for Rolex, a red and blue ceramic bezel on its Oyster Fig. 11 Hublot’s ‘Magic Gold’ watches Fig. 12 The Chanel J12-365 in black Fig. 13 Gucci uses black ceramic for the ceramic case and bracelet used on Perpetual GMT-Master II (Photo Rolex SA) are produced from porous boron ceramic with steel accents and its G-Chrono range (Photo Guccio the new limited edition HyperChrome carbide impregnated with gold (Photo diamond inlay (Photo Chanel SA) Gucci S.p.A) Automatic Chronograph introduced in Hublot SA) 2015 (Photo Rado Watch Co. Ltd.)

designers have contrasted the matt Cerachrome bezel inserts in blue and to be a significant technical achieve- This is done before sintering so that, uses a white ceramic, which, after pores and creating a ‘fusion’ of the brown high tech ceramic case with a green in addition to black in 2007. In ment on two counts. Red is a difficult during the course of the sintering plasma treatment, attains an unique two to produce Magic Gold (Fig. 11). polished rich brown bezel, engraved 2010, Rolex developed a monobloc colour to obtain by Ceramic Injection step, the added compounds react metallic grey look (Fig. 10). A feature with a tachometric scale and filled Cerachrom bezel, rather than a bezel Moulding and, having succeeded with the basic elements of the red of the Grey Side of the Moon is its Chanel with white Super-Luminova. insert, for the Cosmograph Daytona in doing so, Rolex then found a Cerachrom insert to produce the final Super-LumiNova tachymetric scale Fashion house Chanel began using timepiece. In 2014 the company way to locally modify the chemical blue colour. on the brushed ceramic bezel. ceramics in 2000 and the company Rolex introduced a red and blue Cerachrom composition of each grain right to has been credited with making Rolex, which has workshops at bezel (Fig. 8) for its Oyster Perpetual the core of the ceramic. In this way, Omega Hublot ceramic watches fashionable Plan-les-Ouates on the outskirts of GMT-Master II, echoing the first colour changes from red to blue from Another breakthrough with coloured Hublot, Nyon, Switzerland, has been through the use of black zirconia in Geneva, adopted black ceramic bezels GMT-Master bezel of 1955. one half to the next ensuring a sharp ceramics in 2014 came from Bienne- using Ceramic Injection Moulding the iconic J12 watch. White ceramic in 2005 and introduced its exclusive The red and blue bezel is claimed delineation between the two colours. based Omega (part of the Swatch since its Big Bang watches were was introduced by Chanel in 2002. Group) with the introduction of the introduced in 2005, featuring polished Currently the fashion brand uses company’s Seamaster Planet Orange and satin black and white zirconia as Ceramic Injection Moulding not only Ceramic (Fig. 9). This features a well as developing new colours such for watch cases and bracelet parts, bi-directional rotating bezel with 24 as bright red and yellow. In 2012, the but also in the mechanisms. Some hour gradations on a polished ring company introduced a new patented Chanel models use a ceramic rotor made from orange ceramic. Technical ‘Magic Gold’ alloy on its Big Bang and ceramic tourbillions, the latter ceramics have in the main been Ferrari Limited Edition timepiece. placed on a ceramic plate instead of restricted to black, white or pastel The new material was developed brass. colours with bright colours such as in partnership with the Swiss Federal The latest J12-365 watch case orange missing. Omega stated that Institute of Technology (EPFC) in is available in either black or white, it took two years of development and Lausanne and is said to be a fusion depending on the version, and these no less than 3,500 hours of stability of 24 carat gold and boron carbide. are accented with steel or beige tests to obtain the orange colour. This The boron carbide powder is injection gold, with or without diamond inlay was primarily due to problems with moulded to the required preform (Fig. 12). The new shade of 18 carat the pigmentation of intense colours, shape which is then debound and gold is obtained through an alloy but the company persevered and the sintered to create a rigid porous development at Chanel. For its desired result was achieved using structure. After sintering, 24 carat Chromatic line of timepieces, Chanel thermal treatments. gold alloyed with 3% molten liquid developed a cermet material based Fig. 9 Omega’s Seamaster Planet Ocean Orange Ceramic in a brushed and Fig. 10 Omega’s Speedmaster Grey Omega produces its Speedmaster gold is injected under high pressure on titanium and ceramic, which, polished 43.5 millimeter case in 950 grade platinum (Photo Omega SA) Side of the Moon has a ceramic Dark Side of the Moon in black with inert gas at high temperature when polished with diamond powder, case, matt black ceramic dials and zirconia ceramic and the Speed- into the porous boron carbide makes the surface shine in an unique ceramic clasp (Photo Omega SA) master Grey Side of the Moon watch allowing the metal to fill the ceramic way.

Fig. 14 Blancpain uses brushed ceramics for the case and bezel of its Fig. 15 The Royal Oak Offshore Diver Fig. 16 Officine Panerai’s Radiomir Fig. 17 Corum’s latest Golden Bridge Fig. 18 The first Bell & Ross watch Bathyscaphe Flyback watch (Photo Blancpain SA) collection showcases Audemars 1940 3 days Ceramica watch (Photo watches feature slender black with a ceramic case, the BR01, Piguet’s use of white ceramics (Photo Officine Panerai) ceramic curved cases (Photo Corum) introduced in 2014 (Photo Bell & Ross) Audemars Piguet)

Gucci Ceramics’ for the latest in its range Bridge timepieces now incorporate Roger Dubois, Geneva, uses black Collection, the D-Star and the launch ment in new machines and renewal Gucci uses a black ceramic case for of Royal Oak Offshore Diver (Fig. 15) black zirconia curved tonneau shaped ceramics for the bezel on its Easy of the all ceramic Fifty Fathoms of production lines. The company its G-Chrono range using a smaller and Chronograph collections. White cases (Fig.17) combined with a unique Diver Black Swan range and Ulysee Bathyscaphe chronographs. already has over 20 Arburg Allrounder dial, measuring 38 mm rather than CIM parts include the band, bezel, caseback treatment introduced in Nardin recently introduced ceramics Comadur also produces sapphire Powder Injection Moulding machines. the original 44 mm (Fig.13). case middle, pushers and crown. The 2014. The caseback becomes opaque into its Exceutive Dual Time range of crystals and watch stones for the case and band parts are polished and when worn but appears clear when off timepieces. movements manufacturer ETA, rare Hardex Ralph Lauren satin-brush finished. the wrist. earth sintered micro magnets for Hardex, part of France’s IMI Group, is The Ralph Lauren Sporting Chrono- CIM producers play key role quartz watches and micro motors and based in Besançon, Franche-Comte, graph Black Ceramic was the first Officine Panerai Bell & Ross in watch industry polycrystalline micro bearings used in which borders the key watchmaking Ralph Lauren watch with a case The latest version of the Radiomor Bell & Ross introduced its first watch movements or in a wide range region of Switzerland. The company made of ceramic zirconia and which watch, from Officine Panerai, watch with a ceramic case, the BRO1 CIM producers have, of course, played of micro motors. was established in 2006 to access contains a mechanical movement Neuchatel, Switzerland, is its Ceramic, in 2014 (Fig. 18). The black a key role in the development of CIM Comadur saw a marked increase the emerging markets for CIM from Jaeger-LeCoultre. Radiomir 1940 3 Days Ceramica, ceramic case is 42 mm in diameter parts for watches. Key among Euro- in CIM production as a result of components used in watches, as well which has a matt black ceramic case and is close to 50 mm in length with pean CIM producers are Comadur, increased demand and is stated to as luxury consumer products such Blancpain and a minimalist dial inspired by relatively short lugs. The case design Hardex, Chatelain and Formatec, all have completed the internalisation of as pens and jewellery, drawing on Blancpain, also part of the Swatch the brand’s history as a supplier of is based on the older Bell & Ross of which manufacture for the leading raw material (feedstock) production more than 25 years’ experience in the Group and located in Le Brassus in timepieces to the Royal Italian Navy. classic pilot timepieces. It is also Swiss watch brands. for Ceramic Injection Moulding. The manufacture of ceramic parts under the heart of the Swiss Jura, uses a The case and bracelet are made from available in white ceramic for ladies’ company is now said to be completely the name Cheval Freres. 43 mm black satin brushed ceramic matt black zirconia, and the case timepieces. Comadur independent in every phase of CIM Hardex operates a complete CIM case and bezel for its Bathyscaphe measures 48 mm in diameter, and Comadur, based in Col-les-Roches, production. production line, which includes post Flyback watch (Fig. 14). The ceramic offers water resistance to 100 metres Other brands Switzerland, is part of the Swatch It has also established a sintering and assembly operations. unidirectional rotating bezel bears (Fig. 16). Several other leading brands have group. Swatch states that Comadur production line to meet the growing CIM is mostly used for medium hour-markers filled with Liquid- developed ceramic watches. Fendi’s has played an important role over the demands for smaller volumes and volume production, whilst larger Metal®, enabling a perfect bond with Corum Ceramic Chronograph comes in past twenty years in the development ever-more demanding requests volume simple shapes are produced the ceramic bezel. This combination Corum, La Chaux-de Fonds, various hues including blue, white, and manufacture of new CIM watch for new colours. The company will by die pressing and small batches by offers exceptional scratch resistance. Switzerland, is celebrating the 35th brown and black, whilst TechnoMa- parts for models including the Omega continue to upgrade production machining. The company buys in its year since it began producing the now rine offers its Cruise Ceramic in white Speedmaster ‘Dark Side of the Moon’ methods to allow faster set-up times, CIM feedstock from external sources. Audemars Piguet emblematic Golden Bridge timepiece, or black ceramic with the option of and ‘Grey Side of the Moon’ models, also optimising flows between the For post-sintering operations, The family owned company Audemars and the 10th year since the company rose gold or white diamonds on the the Rado DiaMaster and the new Rado various manufacturing operations and Hardex is able to offer surface Piguet, also located in Le Brassus, re-designed the watch. The latest bezel. Modus also offers fashion True collection, the Esenza Ceramic improving product quality, particularly finishing such as high gloss polishing, uses black and white ‘Super Golden Bridge and Miss Golden ceramic watches in white or black. Touch, the HyperChrome Court in the ceramic sector, with invest- brushed finishes, sandblasting, laser

58 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 59 CIM in luxury watches | contents page | news | events | advertisers’ index | email |

engraving and PVD coating. These one of the most important suppliers Today, the company’s CIM operations are essential for high-end of external parts to Switzerland’s production is finely honed and R&D luxury watch products where a perfect luxury watchmakers. The company continues on the development of surface finish is essential. Examples was established in 1947, but has been new finishing processes to create of CIM parts produced by Hardex wholly owned by Chanel since 1993. new surface renditions such as matt for the luxury Swiss watch market This, however, does not prevent it ceramics. include black ceramic top ring and from working with a dozen or so other White, black and grey are currently pushers for the Executive Dual Time clients including Rado. the most widespread grades used by G&F Chatelain given the difficulties inherent in finding a colour that will withstand the high sintering “G&F Chatelain began using Ceramic temperatures. Injection Moulding in 2001 for the References Chanel J12 watch and volume [1] Ceramic injection moulded production of CIM components zirconia products enjoy success in high-value luxury applications, Johan followed six years later” ter Maat et al, PIM International, Vol 4 No 4, December 2010, p 33-37

[2] Success for LÖMI debinding watch by Ulysse Nardin, the CIM G&F Chatelain began using technology in the watchmaking zirconia top ring and back ring for the Ceramic Injection Moulding in 2001 industry, PIM International, Vol 8 No Black Swan watch by Roger Dubois for the Chanel J12 watch and volume 3, September 2014, p 31 and the rear case of the Easy Diver production of CIM components watch also by Roger Dubois [3]. followed six years later. It now also [3] Hardex: Expertise in Ceramic includes movement parts such as Injection Moulded components for G&F Chatelain SA ceramic ball bearings for the barrel, Swiss luxury watches, Nick Williams, Despite its low profile, G&F Chatelain external watch parts, including PIM International, Vol. 6 No. 3, SA, based in La Chaux de Fonds in cases, bezels and bracelet links, and September 2012, p 51-54 the Swiss canton of Neuchatel, is ceramic jewellery rings.

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Sept. 22 – 25, 2015 euromold. Micro Powder Injection Düsseldorf World Fair for Mold- and Moulding: Processes, materials Patternmaking, Tooling, Exhibition Center Design, Additive and applications Manufacturing and Product Development.

From Idea Micro Powder Injection Moulding (MicroPIM) continues to attract to Series Production. attention as a unique process by which to manufacture metal and ceramic micro components in medium to high volumes. In the following exclusive review for Powder Injection Moulding International magazine Dr Volker Piotter and Dr Tassilo Moritz present a status report on the technology, from binder developments to best practice in process simulation, injection moulding and sintering. A number of innovative application areas are also reviewed.

Innovations for In recent years micro component diversity, in turn, a wide range of of large quantities of ceramic and manufacture by means of a requirements arise with regard to the metallic materials is therefore replication process has become an materials to be used. increasing. In this context, Powder important economic and technical Silicon and thermoplastics are still Injection Moulding is a very attractive any purpose. field. Injection moulding in particular used most frequently in microsystems option as it has already been is used for the production of both technology. The demand for firmly established in macroscopic individual micro components with processes that allow the production production [6, 7, 8, 9, 10]. New trends and products at Euromold typical dimensions of ≤ 1 mm as well as microstructured components, that – in Düsseldorf. is to say micro or even nanoscale structures on larger carrier surfaces. This is primarily due to Euromold is the world’s leading marketplace for new products. From the technology’s high efficiency in engineering and mouldmaking to 3D printing, all international key play- medium or large series fabrication, the ability to create complex shaped ers and manufacturers gather here to present the best of innovations. pieces, and the wide range of processable materials. The latter Visit Euromold in Düsseldorf and get inspired by the unique diversity issue in particular corresponds very of new products! closely to the trend towards further diversification in micro manufacture, most notably a tendency towards using more varieties of functional or high-strength materials. This trend can be attributed to the current extremely wide range of application

areas for microsystems technology Fig. 1 A CIM microturbine stator manufactured from ZrO2 demonstrating what products [1, 2, 3, 4, 5]. From this can be achieved with MicroPIM technology (Courtesy KIT)

nonferrous metals, such as copper, titanium, tungsten and tungsten alloys. MicroPIM mostly uses powders with ultrafine or low particle diameters. In the case of ceramic

powders, typical D50 values are in the range of 500 - 800 nm for aluminium oxide and 300 - 500 nm for zirconium oxide. Moreover, several experiments have been performed to manufacture bimodal mixtures from conventional ceramic powders and extremely fine nanopowders to achieve higher powder contents and better contour moulding [14]. In contrast, steels have typical Fig. 2 Mould filling simulation of CFEL micro ceramic Fig. 3 Calculation of maximum shear rates to identify D50 values in the range of 1.5 µm to sections of probable powder-binder segregations Fig. 4 Micro-switch for development of flexible joints of single and multi- nozzle (outer tube with guiding features inside) showing 4.5 µm and these values can also material combinations (left: ATZ/zirconia; right: steel 17-4 PH/zirconia) prediction of flow front temperature to avoid distinct weld often extend into the range up to 10 lines. Hole diameter at tip < 100µm (see dashed arrow) µm or above. For the major MicroMIM stainless steels 316L and 17-4PH, with corresponding consequences tools. A flexible tool design, ensuring When moving from macro to systems influence this flowability and debinding in hexane is required the finest fractions available on the in terms of part quality. To a certain an easy exchange of wear-relevant micro dimensions, however, some thus play an important role in the in most cases. Due to its high market are <5 µm. extent, this can be avoided by components, can improve this points have to be considered. moulding process. flammability and environmental To ensure a sufficiently high choosing larger gate dimensions or situation. In view of the use of rather Micro component manufacture is Additionally, the strength of risks, hexane is poorly suited for use powder content and acceptable by using hot runners for the sprue soft tool materials, this applies to characterised by: green parts must be considered with outside a laboratory environment. feedstock flowability, powder particles and runner system. In this context, MicroPIM in particular. MicroPIM. Due to their relatively large Therefore, a new two-component are preferably globular. The spherical • Higher surface-to-volume ratios it is important to note the so-called A further important issue concerns surface-to-volume ratios but small binder has been developed at shape, moreover, largely prevents variothermal tempering, which, prior dimensional accuracy, which is • Faster cooling and freezing of load-bearing cross-sections, the Karlsruhe Institute of Technology orientation effects in spite of the to injection, heats the mould core to determined, among other factors, feedstocks components are subjected to high (KIT), Germany, that contains high- shear rates, which are generally temperatures near to the feedstock by the sintering procedure. To keep • Higher demoulding forces relative forces during debinding. molecular polymethylmethacrylate higher in MicroPIM . melting point and cools it down again sintering shrinkage low, maximum to the load-bearing cross-section As in macroscopic PIM technology, (PMMA) as the structural polymer, • Higher shear rates than in further factors of significance are, low-molecular polyethylene glycol The shaping step for instance, feedstock homogeneity, (PEG) as the plasticiser and macroscopic runners The rheological and thermodynamic shelf-life and recyclability, easy and dispersants as additives [12]. Since “zirconium and aluminium oxide • Abrupt changes of runner properties of PIM feedstocks clearly ecologically safe debinding, and PEG dissolves readily in cold water, sections. differ from each other with regard to controlled shrinkage behavior. this binder is environmentally powders are most commonly used viscosity and thermal conductivity. The most widely used binder friendly. The approach was These characteristics, among others, in MicroPIM, with well established Unique aspects of Micro systems are based on polyolefines developed as an extrudable generate particular technological Powder Injection Moulding and paraffin wax. Adaptation to thermoplastic mixture (PMMA/ MicroPIM features, which, in certain applications being fiber-optic ferrules the specific demands of MicroPIM PEG4000). In the meantime, the cases, even differ from the micro Feedstocks is performed by optimisation new binder concept has also been and wire bonding nozzles” injection moulding of polymers, Micro Powder Injection Moulding of composition of binders and successfully implemented with which, in parallel, is also undergoing (MicroPIM) makes great demands appropriate adjustment of the polyvinylbutyral/PEG [13]. steady progress [15]. after the filling step to enable ejection powder content is sought. This is, on both binder ingredients and powder-binder ratio. Importance has to be attached, for of a dimensionally stable part. A however, limited by the consequently feedstock composition. For example, Moreover, the addition of surface- Powders example, to the appropriate design detailed description of this processing increasing viscosity of the feedstock. particles in the micrometre or even active substances (dispersants) With reference to ceramic materials, of sprues and runners, gate sizes, methodology is given in [18, 19]. The Therefore, the precise control of the sub-micrometre range are required to binders allows for a significant zirconium and aluminium oxide numbers of cavities and the posi- relevant micro-specific aspects, physical effects occurring during in order to fulfil demands of MicroPIM viscosity reduction and a much better powders are most commonly used tioning of ejectors. In micromoulding, such as the variothermal tempering sintering determines the exact component surface roughness, feedstock homogeneity. To achieve in MicroPIM, with well established the general PIM design guidelines [16, or the often applied tool evacuation, dimensional tolerances. This issue feature detail and mechanical total coverage of the powder particles applications being fibre-optic 17] have to be observed at least as can be implemented using upgraded presents a basic challenge for all properties. This extraordinarily small with dispersant [11], the portion of ferrules and wire bonding nozzles. strictly as in the macroscopic world. systems offered by some equipment sintering methods and, thus, also for powder grain size, in turn, influences additives ideally corresponds to the Nitride ceramics, such as silicon The accelerated formation of manufacturers. MicroPIM [20]. the composition of the binder entire feedstock powder surface. nitride, are still at an early stage of a cooled surface layer and the Surprisingly little is found in To roughly outline the technical systems. As a first consideration, A major drawback of the development. The primary metals premature freezing of the gate that the literature with regard to the performance of MicroPIM, Table 1 feedstocks showing a very good polyolefine/paraffin system, however, utilised are PM stainless steels, can be observed during injection, obvious fact that highly filled ceramic lists several critical dimensions for flowability are required. Binder is the fact that preliminary chemical such as 17-4PH and 316L, and reduce the holding pressure time feedstocks induce higher wear on different classes of materials. As is

Multi-component PIM

It is clear to see that the assembly of different individual pieces into complete systems is an elaborately complex, and thus costly, process. This is an especially important consideration in micro dimensions. If, in addition, one considers the fact that in microsystems engineering multifunctional components consisting of several components are also increasingly needed, it becomes evident that new process variants have to be developed. Fig. 5 Tool insert for micro in-mould embossing Fig. 6 Sintered zirconia disc consisting of a black zirconia Probably the most prominent Fig. 7 Ceramic micro-caps with pressure sensitive ceramic membrane in the tape embossed by injecting a white zirconia feedstock example is the so-called as-fired state prior to electrical conducting steps two-component micro injection evident from the parameters, the Moldex 3D®, Sigmasoft®, and The entire modelling of all physical moulding process [26], where at least the degree of shrinkage of the inner Fig. 4 shows a micro-switch made low particle sizes of the ceramic PIMSolver®. These programs all use and chemical effects occurring during two different feedstocks are injected section is higher. Only under such of the material combinations steel materials compared with those of the the finite-element method, mainly the different PIM steps, however, was simultaneously, or at different times, conditions, and with an appropriate 17-4 PH/zirconia and ATZ/zirconia, metal powders have a positive effect. applying volume model networks. and is still a matter of research [23, to form a composite component tool design, can a gap enabling respectively. The best moulding results, however, However, it should be emphasised 24, 25]. Nevertheless, if the limita- during moulding. The compound sufficient rotary motion be formed Another promising option for the are achieved with pure polymers. that the reliability of such simulations tions described above are taken into parts obtained in this way consist between the gear wheel and the shaft combination of different materials completely depends on an adequate account, the use of simulation tools mainly of a combination of materials [29]. by micro PIM is given by micro Simulation materials model. Here the first diffi- allows mould filling processes to be with different properties that may For the development of flexible in-mould labelling (micro IML). For Computer-aided simulation of culty occurs; although PIM feedstocks analysed in advance to an acceptable well be opposed to one another, joints of micro components, a special this approach, a thin ceramic or manufacturing processes allows consist of at least two phases, most degree. Additionally, important with examples being electrically testing tool has been constructed metallic green tape, made by tape determination, prior to production, commercial programs use one-phase physical parameters, such as shear conducting/insulating or magnetic/ at Fraunhofer IKTS. The so-called casting, is inserted into the cavity of the general applicability of models. One consequence of this stress and shear rate, can be deter- non-magnetic [27, 28]. Combining micro-switch tool allows the of the injection moulding tool. Next, certain methods and of the process is that typical PIM effects, such as mined, leading to useful predictions multi component injection moulding parameters to be expected. It is powder-binder segregation, cannot as to the sections of the parts where with MicroPIM, one obtains the 2C due to this fact that simulation has always be predicted adequately. As calamities might occur. micro Powder Injection Moulding already been used for many years the launch of entirely new programs A good example is given in a method (2C-MicroPIM). “By using this tool, flexible joints of in macroscopic engineering [21]. is costly, software developers usually collaborative project between the The process procedure can be a single material may be developed When applied to micro systems modify their existing systems. An Center for Free-Electron Laser carried out in at least two principally technology, it is important to consider interesting approach in this context is Science (CFEL) at DESY, Hamburg and different variants, depending on by combining either feedstocks with that subsequent modifications of, for to operate with a model which takes KIT, which was aimed at developing whether flexible or permanent joints instance, LIGA moulding tools are into account collision-induced flux twin-tube ceramic nozzles to be used are required. Permanent joints must different shrinkages, or different virtually impossible, so design errors and viscosity-induced flux. Such an in experiments with X-ray free-electron have defined bonding surfaces, for materials, such as stainless steel and must be resolved at an early stage. approach has just been introduced lasers. Such nozzles are required to instance, between gear wheels and Several commercial software by Sigmasoft and initial results generate a strongly focused liquid jet shafts. To ensure that stresses and zirconia” programs are available for the are very promising, as typical PIM of the analysis sample perpendicular strain in the two components are simulation of plastic processing, with effects, such as plug-flow, can be to the beam of intense femtosecond reduced to a minimum, the material leading examples being MOLDFLOW®, predicted [22]. pulses of X-rays (Figs. 2, 3). selection and process procedures must be adapted in such a way that sequential injection moulding of an the ceramic or metallic feedstock is the partial components are sintered outer C-shaped guiding component injected and combined with the green Minimum lateral Min. details Aspect Ratioa Tolerancesb Surface roughnessc Material almost simultaneously. This requires and an inner flexible micro-disc. tape. The injection step also offers the dimensions [µm] [µm] sunken structures [%] Rmax/Ra [µm] that all components are largely The inner diameter of the guiding possibility to attain a microstructuring identical as regards the degree of component is 2.5 mm. By using of the green tape by using the applied Metals 25 10 > 10 ≤ ±0.4 7/0.8 shrinkage and the sintering kinetics. this tool, either flexible joints of a injection pressure of the feedstock Ceramics ≤ 10 < 3 15 ± 0.1 - ±0.3 < 3/0.2 For flexible joints, conditions single material may be developed by and by a certain inner tool surface are almost the reverse. The combining feedstocks with different microstructure. This additional Polymers 10 ≤ 0.08 25 ±0.05 0.05/0.04 process parameters and material shrinkages, or different materials, option of microstructuring is named a = AR, corresponds to flow path-to-wall thickness ratio b = reproducibility of nominal size combinations must be selected in such as stainless steel and zirconia, in-mould embossing. A testing tool c = dependent on the type of mould insert such a way that sintering of the inner electrically conductive and electrically for this technology has been designed Table 1 Important parameters reflecting the present state of MicroPIM. The corresponding values for micro injection section starts earlier than sintering of insulating ceramics or differently and constructed by Fraunhofer IKTS moulding with pure polymers are added for comparison the outer section and that, in addition, coloured ceramics can be combined. within a project funded by the German

manufactured with little or no Authors [6] T. Moritz, R. Lenk, Ceramic ceramic injection moulding. Microsyst post-sintering treatment injection moulding, a review Technol 20 (2014), pp. 51-58. • The opportunity of combining Volker Piotter of developments in production [13] O. Weber, T. Hanemann, injection moulding with semi- Karlsruhe Institute of Technology technology, materials and Green-conscious ceramic injection products produced by other (KIT) applications. Powder Injection moulding. Advanced Processing shaping techniques such as tape Institute for Applied Materials Moulding International, Vol. 3 (3), and Manufacturing Technologies casting (IAM-WK) Inovar Communications Ltd. (2009), for Structural and Multifunctional Hermann-von-Helmholtz-Platz 1 pp. 23-34. • The commercial availability of Materials VI; (Eds. T. Ihji, M. Singh, 76344 Eggenstein-Leopoldshafen production equipment. [7]V. Piotter, A review of the current M. Halbig, S. Mathur, Hoboken, USA; Germany status of MicroPIM, John Wiley& Sons (2013), pp. 63-71. The different binder systems [email protected] available today for the development Part 1, Materials, processing, [14] J. Rajabi, N. Muhamad, A.B. microspecific considerations and Sulong, Effect of nano-sized powders of feedstocks enable both the Tassilo Moritz applications, Powder Injection on powder injection moulding, a manufacture of ceramic and metallic Fraunhofer Institute for Ceramic Moulding International, Vol. 5, No. 3, review. Microsyst Technol 18 (2012), microstructured components. Newly Technologies and Systems (IKTS) Inovar Communications Ltd. (2011), pp. 1941-1961. developed binders such as PMMA/ Winterbergstr. 28 pp. 27-36. PEG or PVB/PEG allow the use of 01277 Dresden [15] C. Hopmann et al., Process water as a solvent for the chemical Germany Part 2, Screw injection units, Development for the Production of Fig. 8 Testing components for injection moulded microstructures made of preliminary debinding and, hence, [email protected] simulation and process variants, Plastics Parts with Micro Features. coloured sintered glass powders can be considered environmentally Powder Injection Moulding Proc. of 4M/ICOMM2015 Conference, friendly. International, Vol. 5, No. 4, Inovar Research Publishing, Singapore,

Among the major trends in further Acknowledgments ISBN, 978-981-09-4609-8 (2015), pp. Federal Ministry for Economic Affairs As well as ceramics, other Communications Ltd. (2011), pp. micro Powder Injection Moulding 3-8. and Energy (KF2087326AG1). In this materials, such as glasses, can The authors wish to thank all their 25-30. development is the optimisation case, the green tape is embossed be processed by micro injection colleagues at KIT and IKTS, especially [8] R.M. German, Markets [16] R.M. German, Powder Injection of process control at all process by the injection pressure of the moulding. As an example, micro- Mr. A. Klein, as well as their external applications, and financial aspects Molding - Design and Applications. stages, particularly with regard to feedstock and by a tool insert showing structured testing components partners for the friendly and always of global metal powder injection Published by Innovative Materials the reduction of demixing effects different alphabetic characters and made of coloured glasses are shown helpful cooperation. molding (MIM) technologies. Metal Solutions, Inc., ISBN 0-9727642-0-8 that are considered the main cause geometrical shapes with different in Fig. 8. These components have Powder Report January/February (2003). of deformations and dimensional depths (100, 300, 500, 1000 microns) been developed by IKTS and Inmatec 2012, 0026-0657 (2012), pp. 18-26. [17] D.F. Heaney, Designing for metal imprecisions. In addition, efforts References as shown in Figs. 5 and 6. Technologies GmbH in a project injection molding (MIM). In, Handbook are being made to improve the [9] J. Zhang, M. Sahli, J.-C. Gelin, C. called Colorglass (KF2087345CK3, [1] F. Petzoldt, Micro Powder of Metal Injection Molding, Editor D.F. dimensional accuracy of the sintered Khan-Malek, Experimental analysis KF2166905CK3), funded by the Injection Moulding – challenges Heaney, Woodhead Publishing Ltd., Applications and case parts to below ± 0.1%. In this context, of the evolution of the physical German Federal Ministry for and opportunities. Powder Injection Cambridge UK, ISBN 978-0-85709- it is important, moreover, to mention properties of pyramidal-shaped studies Economic Affairs and Energy. Moulding International, Vol. 2, No. 1, 066-9, (2012), pp. 29-63. the upgrading of existing software metallic replicas made using the MIM Inovar Communications Ltd. (2008), Within the project CeraHOT (No. programs through implementation of process. Int J Adv Manuf Technol 68 [18] S. Kuhn, A. Burr, M. Kübler, M. pp. 37-42. 100118509), funded by the Free State Outlook MicroPIM-specific effects. (2013), pp. 1063-1074. Deckert, C. Bleesen, Study on the of Saxony, a pressure sensor has Another essential trend is the [2] V. Piotter, W. Bauer, T. Hanemann, [10] A. Islam, N. Giannekas, M. replication quality of micro-structures been developed which was covered by MicroPIM provides the possibility of development of finer powders for M. Heckele, C. Mueller, Replication Marhöfer, G. Tosello, H.N. Hansen, in the injection moulding process with a ceramic micro-cap with a pressure combining the material properties MicroPIM, by providing feedstocks technologies for HARM devices, status A Comparative Study of Metal dynamical tool tempering systems. sensitive ceramic membrane. This of metal and ceramic materials with additives of ultrafine or and perspectives. Microsyst Technol and Ceramic Injection Moulding Microsyst Technol 16 (2010), pp. micro-cap was made of alumina with with the high economic efficiency of nanodisperse fractions, to obtain still 14 (2008), pp. 1599-1605. for Precision Applications., Proc. 1787-1801. an outer diameter of 5 mm consisting the increasingly established micro smaller details and higher surface [3] R.M. German, Materials for of 4M/ICOMM2015 Conference, [19] S.Y. Choi, N. Zhang, J.P. Toner, of a supporting ring with an inner injection moulding method. The qualities. Microminiature Powder Injection Research Publishing, Singapore, G. Dunne, M.D. Gilchrist, Effect diameter of 1.25 mm and the pres- attractiveness of this symbiosis is Last but not least, there are Molded Medical and Dental Devices. ISBN, 978-981-09-4609-8 (2015), pp. of Vacuum Venting Process on sure sensitive ceramic membrane mainly thanks to: different approaches to manu- Int. Journal of Powder Metallurgy, Vol. 567-570. Replication of Nano/Micro-Features in with a thickness of only 250 microns. • A very high economic efficiency facturing multi-component micro 46, 2 (2010), pp. 15-18. [11] T. Hanemann, R. Heldele, T. Microinjection Moulding, Quantitative In further processing steps, this in the case of medium and large parts, by for example conventional [4] G. Schlieper, Innovation helps Mueller, J. Haußelt, Influence of and Qualitative Analysis. Proc. membrane was equipped with a thin series production two-component PIM or methods producer of CIM products for luxury stearic acid concentration on the of 4M/ICOMM2015 Conference, electrical conductive platinum layer in such as in-mould labelling with Research Publishing, Singapore, • The current and future applications expand into new processing of ZrO2-containing an appropriate geometry for trans- PIM feedstocks (IML-MicroPIM) [30, ISBN, 978-981-09-4609-8 (2015), pp. availability of a wide range of markets. Powder Injection Moulding feedstocks suitable for micro powder forming the mechanical deformation 31], and sinter joining [32]. These 262-265. non-polymeric materials International, Vol 6, No 1 (2012), pp. injection moulding. International of the membrane due to the pressure approaches are not only economi- 47-51. Journal of Applied Ceramic [20] V. Piotter, A. Klein, T. Mueller, K. difference into electrical signals. • The possibility of using func- cally efficient thanks to a reduction [5] J.H. Kim et al., Manufacture of a Technology, 8(4) (2011), pp. 865-872. Plewa, Manufacturing of integrative The component was made by micro tional materials such as hard/ in assembly steps, but also provide micro-sized piezoelectric ceramic [12] T. Hanemann, O. Weber, membrane carriers by novel powder injection moulding and weighed only ductile or insulating/conductive multifunctional components which structure using a sacrificial polymer Polymethylmethacrylate/ injection moulding. Microsyst Technol 85 mg. Fig. 7 shows the as-sintered materials otherwise cannot easily, or in some mold insert. Microsyst Technol 19 polyethyleneglycol-based partially (2015), DOI 0.1007/s00542-015-2563-y. micro-cap prior to grinding and • The fact that components with cases cannot at all, be made by any (2013), pp. 343-349. water soluble binder system for micro [21] M. Thornagel, MIM-Simulation, platinum layer coating. complex geometries can be other process.

68 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 Vol. 9 No. 3 © 2015 Inovar Communications Ltd September 2015 Powder Injection Moulding International 69 MIM2016_ad_A4_Layout 1 8/25/2015 1:28 PM Page 1

Benefits of Advanced Rheology of 4M/ICOMM2015 Conference, Kleissl, J. Hausselt, Development International Conference on Injection Molding Models; Proc. Euro PM2011, Vol. Research Publishing, Singapore, of Two-Component Micropowder of Metals, Ceramics and Carbides 2, European Powder Metallurgy ISBN, 978-981-09-4609-8 (2015), pp. Injection Moulding (2C MicroPIM), Association, Shrewsbury, UK, ISBN 322-325. Characteristics of Applicable MARCH 7–9 • HOTEL IRVINE 978-1-899072-21-7 (2011), pp. [25] L. Liu et al., Flow analysis of ZrO2 Materials. International Journal of 6 IRVINE, CA 201-206. microarray in micro powder injection Applied Ceramic Technology, 8(1) [22] M. Thornagel, V. Schwittay, molding. Advanced manuscript in (2011), pp. 194-202. G. Hartmann, Powder-Binder Proc. of PowderMet 2015, San Diego, [30] E. Vorster, V. Piotter, K. Plewa, Segregation, PIM-Simulation at MPIF (2015). A. Kucera, Micro Inmould Labelling Breakthrough. Proceedings of Euro [26] A. Islam et al., Two-component Using PIM-Feedstocks. Proceedings PM 2014 conference, published by micro injection moulding for hearing of Powder Metallurgy 2010 World Make plans to attend EPMA Shrewsbury, UK, ISBN 978-1- aid applications. Int. J. Adv. Manuf. Congress, EPMA, ISBN, 978 1 899072 899072-45-3. Recession can also be Technol. 62 (2012), pp. 605-615. 13 2, Vol. 4 (2010), pp. 505-510. the only international found in PIM International Vol. 8 No. 4 [27] F. Petzoldt, Multifunctional parts [31] A. Mannschatz, A. Härtel, (2014), pp. 67-69. by two-component Powder Injection A. Müller-Köhn, T. Moritz, A. [23] D. Kauzlaric, L. Pastewka, H. Moulding (2C-PIM). Powder Injection Michaelis, M. Wilde, Manufacturing metal and powder Meyer, R. Heldele, M. Schulz, O. Moulding International, Vol. 4, No. 1 of Two-colored Co-sintered Zirconia Weber, V. Piotter, J. Hausselt, A. (2010), pp. 21-27. Components by Inmold-labelling and 2C-Injection Molding. cfi/Ber. DKG 91 Greiner, J.G. Korvink, Smoothed [28] M. Mulser, G. Benedet Dutra, injection molding (2014) No. 8, E1-E5 particle hydrodynamics simulation J. Rager, F. Petzoldt, Influence of shear-induced powder migration of a Mismatch in Shrinkage for [32] K. Klimscha, T. Müller, J. in injection moulding, Phil. Trans. R. Two-Component Metal Injection Fleischer, Analysis of the influence of event of the year! Soc. A, 369, 2011, pp. 2320-2328. Moulding (2C-MIM); Proc. World PM sinter temperature on the joint quality [24] D. Claudel, M. Sahli, J.C. Gelin, 2010. 10.-14.10.2010, Florence, Italy, of sinter-joined microcheck valves Shrewsbury, EPMA, 2010, Vol.4 (2010), made of 17-4 PH stainless steel. Int T. Barriere, An Inconel based MIM2016 CONFERENCE feedstock and its Identification of pp. 527-534. J Adv Manuf Technol 72 (2014), pp. 173–178 rheological constitutive model for [29] A. Ruh, T. Hanemann, R. (March 7–9) powder injection moulding. Proc. Heldele, V. Piotter, H.-J. Ritzhaupt- A two-day event featuring presentations, plant tour and a keynote luncheon • Innovative Processes & Materials • Dimensional Accuracy and Consistency • Advances in Component Uniformity • Part Selection—Best Practices • Leading Process Trends • Tabletop Exhibition & Networking Reception with Representatives from Many of the Leading Companies in the Field for the world of ...and Much More! POWDER Optional One-Day Powder Injection Molding Tutorial Precedes Conference (March 7) METALLURGY Taught by Randall M. German, FAPMI world-renowned PIM expert This conference is sponsored by the An ideal way to acquire a solid grounding in powder Metal Injection Molding Association, injection molding technology in a short period of time a trade association of the Metal Powder Industries Federation • Introduction to the manufacturing process • Definition of what is a viable PIM or MIM component POWDER • Materials selection and expectations METALLURGY • Review of the economic advantages of the process ipmd.net REVIEW Visit mim2016.org or mimaweb.org for complete program details and registration information

70 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 | contents page | news | events | advertisers’ index | email | Lithoz: AM of Ceramics 3rd International Additive Manufacturing of Conference in Kyoto, Japan Ceramics: Opportunities and solutions for the CIM industry

The Additive Manufacturing of ceramics has the potential to not only transform the way the ceramic industry addresses prototype development, but also presents an opportunity to open up new applications that until now APMA 2015 were impossible to produce with conventional ceramic technology. In this Date extensive review, Dr Johannes Homa and Dr Martin Schwentenwein from ̶ Austria’s Lithoz GmbH present the state of the art in ceramic AM and review Nove:mber 8 (Sun) 10(Tue), 2015 the technical and commercial considerations with specific relevance to the CIM community. Venue: Kyoto University Clock Tower Centennial Hall

Additive Manufacturing (AM) is now of industrial production, where huge manufacturing technologies, which well known amongst those involved factories disappear and everybody have been used and optimised over in industrial manufacturing, as well manufactures the required goods at many decades and even centuries? as wider society, thanks to numerous home. Will this really happen or is this The ceramic industry could perceive magazine cover stories and huge scenario just a newspaper hoax or an this as a threat because its traditional on Powder media interest. A wide variety of excessively enthusiastic outlook of the processes are so complex and applications has been reported, future? Can AM replace all traditional elaborate. from weapons to organs and even entire buildings. While some of these applications might need a Metallurgy few more years to become a reality, the question is always raised as to whether AM will be the standard manufacturing process of the future. AM technology has already in Asia had an enormous impact on a number of areas such as dental, medical, and aerospace technology. Additionally, budget 3D printers are available for the mass consumer market and their use could turn the traditional ways of manufacturing upside down. Consumers are now in the position to produce their own products, which some suggest could lead to a decentralisation of production. Some commentators Organized by claim that a new age has arrived Fig. 1 A range of additively manufactured ceramic components produced on and we will see a democratisation Lithoz’s Cerafab system Japan Society of Powder and Powder Metallurgy (JSPM)

time and costs for the production of size of the part. This determines how the tool can be saved. In particular, many parts can be built in parallel tools for Ceramic Injection Moulding and how long it takes to finish one are very expensive and have very long run. Different case studies have lead times. Consequently, in tradi- shown that the break-even point tional forming, CIM is typically used varies and might range from a few when complex parts are required in dozen to tens of thousands of parts, large quantities, but it is very difficult depending on the application. for the process to make cost-effective However, all these considerations prototypes or small scale series. become irrelevant if the material Sometimes, however, it is necessary properties of the AM parts do not to have just a few parts in order comply with the characteristics of to test an idea or for iterations to conventionally formed parts. Thus, achieve an optimised design. In such the ultimate key requirement is to cases, AM could be the method of meet the quality criteria of conven- choice and act as a supplement and tional manufacturing processes. ‘door opener’ for the CIM industry. It only makes sense to use AM as As shown schematically in Fig. 2, the an addition to traditional forming costs for AM parts are independent technologies if the material proper- Fig. 2 Cost effectiveness for prototypes and small scale series Fig. 4 Cost versus complexity for AM and CIM of their quantity and the costs for ties and the geometrical tolerances CIM parts decrease with increasing are sufficient. The technology could The advantages of Additive no mould is required to create numbers. Consequentially, there is a then support the development of new Manufacturing the desired shape and the part is break-even point up to which AM is products because designs can be directly created from a CAD file. The more cost effective than CIM. This is, easily altered and the parts can be What is beyond dispute is that AM machining process on the other hand of course, an oversimplification and a evaluated under real-life conditions. has a huge potential for the future doesn’t require the usage of product- number of different parameters need The first tests can be performed and has many advantages compared specific moulds, but it does take time to be taken into account. However, using different designs and feedback to traditional ceramic forming to prepare the tool path for the CNC it gives a first-order indication of loops and new iterations can be the potential of AM. Additionally, implemented very efficiently. For the time for producing the mould, example, the Vienna University “What is beyond dispute is that AM which might be up to ten weeks of Technology (VUT) is currently depending on design complexity and developing a ceramic blood pump, has a huge potential for the future and special requirements, could be saved. where the design was subjected This increase in efficiency has the to more than 15 alterations [1]. As has many advantages compared to potential to significantly speed up the shown in Fig. 3, it is not only major traditional ceramic forming processes” development and production cycle of a design iterations that have been new product. made, but also minor changes that It is very difficult to determine this were necessary to meet specific Fig. 5 Cellular structure made by AM processes. The major advantage of machining and critically not every break-even point in general. There are requirements during the different AM is that it is based on a tool-less design can be machined. two main drivers that play a crucial development stages. and the effort required in cleaning. Even with subtractive methods, such production process. Unlike other A tool-less manufacturing process role. For CIM, it is the complexity of However, in most cases, the influ- as turning or milling, it is not possible ceramic forming processes such as is well suited to prototype and small- the part, which in turn determines Embracing complexity ence of complexity on the costs of to fabricate every required design. injection moulding or slip casting, scale series production because the the costs of the tool. For AM, it is the a given AM component is negligible A part such as the one shown in As already mentioned, another limi- when compared to conventional Fig. 5 cannot be produced by CIM or tation of tool-based manufacturing manufacturing techniques. Hence, by machining, but only by AM. It is technologies is the increasing cost there is again a break-even point impossible to demould this part or with increasing design complexity. in this model where the choice of to create the pore structure with a If the mould design is more using AM over CIM becomes more tool. Such a structure can however be complicated and consists of multiple cost effective. This statement on its used for scaffolds with defined pore individual parts, it will consequently own is already an important finding, geometry and size, catalyst carriers become more expensive. As shown but much more interesting is the or lightweight structures. These in Fig. 4, the costs per unit for AM, in asymptote which can be observed are only the obvious applications, contrast to CIM, are independent of for a certain complexity for CIM but there is much more potential in the complexity of the part. Again, this produced parts. It indicates that some this new design freedom. Prevailing statement is an oversimplification, designs are simply not feasible with design limitations with conventional because the costs are dependent on tool-based manufacturing processes manufacturing technologies can be many different parameters such as because of the unavoidable step of overcome and the design process can Fig. 3 Design alteration of the ceramic blood pump developed by Vienna University of Technology (Scale 2:1) the addition of support structures removing the part from the mould. be focused on functionality.

tion of assembly costs or indirect savings because of the better performance of an AM produced Building-Platform part. As long as traditional forming technologies can be easily applied for mass production, AM will in most cases be more expensive, slower Wiper blade and not as accurate. AM should therefore be seen as a supplement for traditional forming technologies and as a means of overcoming Vat current manufacturing limitations - both from an economical and a technological point of view. Fig. 6 is an example of a design that cannot Light-Engine be manufactured using traditional forming technologies. The part is a blood pump with two bearing points. Fig. 6 Blood pump with two bearing points which can only be produced by AM Fig. 8 Building chamber of the CeraFab 7500 (left) and schematic structure (right) In this case, it is necessary to use AM to produce this geometry since Generally speaking, AM enables a task for these engineers to move this design gives additional benefits one will believe that one can use a Additive Manufacturing of in most cases not really desirable paradigm shift from manufacturing- beyond the conventional design rules such as increased operational design developed for dry pressed ceramics because of a detrimental microstruc- oriented design towards design- and embrace the new options. stability. parts and injection mould it without ture. Furthermore, high stresses oriented manufacturing. This does It must, however, be emphasised As has been demonstrated, CIM encountering any problems. It will Before AM is accepted by the are generated through the melting not mean that AM has no design that the traditional manufacturing or any other traditional forming take some time to understand a new ceramic industry, however, another of each layer on top of the existing limitations at all, but it does allow technologies will in no way become technology will not be replaced by forming technology and to identify its very important condition has to be structure and ceramics, in contrast the engineer to design differently. obsolete. The majority of functional AM, but AM could bring additional advantages and disadvantages. fulfilled. The material properties of to metals, cannot be annealed. The Products that in the past required a parts will still be produced by benefits for the production of Curiously, AM is seen completely the AM parts should be comparable to indirect approach, where ceramic labour-intensive assembly can now traditional forming processes, but prototypes or small scale series. differently by many people. It is those made by conventional ceramic powders are coated with a polymer be manufactured in a single part. there will be some applications where Moreover, AM could be implemented expected to be the miracle tech- forming technologies. Focusing on and only this polymeric binder is Additional functionalities can also AM will be advantageous, and some as a tool to support the develop- nology, where the above mentioned structural ceramic parts, strength fused together has problems in be integrated in a single part and where AM will be the only viable ment and sales of new ceramic considerations should no longer be and density are the most important achieving dense parts, because green thus new ideas and designs can be option. Consequently, AM will succeed mass products by providing the valid. This can be mostly attributed to properties. There are several AM density is not sufficient because of the realised. Unfortunately, few examples where the additional benefits that first prototypes in a quick and cost the media hype surrounding this new technologies using ceramic materials. limited compaction of the powder bed. exist in the ceramic industry. Ceramic can be achieved with the new design effective manner. However, much technology. AM has been billed as It is obvious that every technology This is very similar to 3D printing, engineers have been taught in the freedom outperform traditional more important in the long term is the solution to every manufacturing has its respective pros and cons and where a binder is jetted into a powder past to avoid complex structures forming technologies. This does not the opportunity to develop completely problem; a disruptive technology different applications also require bed. and to design their products to be as only include manufacturing costs, but new applications with the newly which turns the production landscape different technologies. If high densi- All powder-based technologies simple as possible. It will be a difficult also the savings due to the elimina- gained design freedom. of the next century upside down. ties and good precision are required, have to use specific powders, AM is of course the latest in a The ceramic industry will need to which is in most cases very important which can be spread easily. Due long line of ceramic forming tech- understand the potential of AM for parts produced by CIM, many to the relatively coarse powders nologies and as with other processes and think about new applications. AM technologies have difficulties in (20–30 µm), which are very often it has its own pros and cons. With The industry has the opportunity to meeting the high standards of the used, the resolution is restricted the advent of CIM in the 1940s, other define the competitive advantage to ceramic industry. and densification is very difficult. ceramic forming processes did not others in dealing and using this new Processes such as laser sintering, FDM or Robocasting have rather suddenly cease to be used. Simple technology. AM should be seen as 3D printing or Fused Deposition anisotropic material properties due geometries are still dry pressed, but a door opener for new applications Modelling (FDM) have already been to the extrusion of the material. Very CIM opened up a completely new with the potential to extend the use of adapted to process ceramic mate- thin nozzles could be used to achieve field of complementary applications ceramics into new markets. There are rials. However, they have difficulties good resolution, but the building which had not been possible before. already a number of success stories in reaching the required material times would consequently become Notably these had, in most cases, to in metal AM where AM has generated properties for dense and precise very long. be developed from scratch. huge benefits for the aerospace, parts. Direct Laser Sintering (or, more The Lithography-based Ceramic Of course, there are some border- dental, medical and tooling sectors, to accurately, laser melting because Manufacturing (LCM) technology, line cases where the limits become name just a few. It is therefore critical it is actually a melting process) is developed by Lithoz, attempts to blurred, but in most situations it for the ceramics industry to gain not really favourable for ceramic follow a traditional ceramic approach becomes very clear which technology experience with AM and develop new materials because the material is to achieve the required properties [2]. Fig. 7 Lithoz’s CTO Dr Johannes Patzer with the CeraFab 7500 should be used. Furthermore, no applications. not sintered but molten and this is Lithoz is currently offering two

fixed wiper blade in combination with a rotating vat. After solidification of each layer, the building platform is moved upwards, the layer is renewed by the recoating system and then the building platform is lowered again. The building platform forms a gap together with the surface of the vat, which corresponds to the thickness of one layer. The slurry in the gap is selectively exposed to visible light to solidify the next cross section. After finishing the whole run by creating the part in a layer-by-layer approach, the part is removed from the platform and cleaned. Since a binder is used, the produced part consists of both ceramic particles and an organic photopolymer network. This green Fig. 11. A graphical target-actual comparison between a LCM produced part therefore needs to be debound structure after debinding and sintering and its underlying CAD design and sintered, as in conventional ceramic forming technologies. The Materials that have already been fracture surface can be seen in Fig. 9 Different parts made by LCM technology debinding is done by heating the part successfully processed by LCM Fig. 10 at various magnifications. No according to a specific debinding range from alumina, silica, zirconia, difference can be seen in comparison dedicated AM systems for the produc- ceramic particles are homogenously almost 100 % of the material that schedule. Subsequently, the part cordierite and glass ceramics to to traditionally formed alumina and tion of high performance ceramic dispersed in a photosensitive is fed into the process is solidified, has to be sintered according to the tri-calcium-phosphate and hyroxyl- it is no longer possible to tell that parts. The CeraFab 7500 (Fig. 7) has resin which is mainly composed which clearly renders this technique requirements of the powder used. apatite for biomedical applications. this part has been manufactured in a a build envelope of 76 mm x 43 mm x of monomers, dispersants and very attractive in terms of costs and This process is well known from Ceramic parts of different materials layer-wise manner. 150 mm, whilst the CeraFab 8500 has photo-initiators. The achievable solid resource efficiency. The schematic traditional ceramic processing and are shown in Fig. 9. Surface roughness after sintering, a build envelope of 115 mm x 64 mm content is to a great extent dependent layout of the CeraFab system is shown the material properties are the same It should be noted that dark without any polishing or grinding, is x 150 mm. on the ceramic powder used and in Fig. 8, with the light engine at the or, at least, very similar to conven- materials are more difficult to well below 1 µm, which is acceptable As with any other AM process, LCM ranges typically from 40 to 60 vol%. bottom of the build chamber. Each tionally formed parts when the same process due to their higher light for most applications. However, the starts with a CAD file of the required Since the slurry is photosensitive, cross-section is exposed through the powder has been used. absorbance. Since the light needs to parts can also be post-machined in part. The part is virtually sliced into the cross-sections are selectively transparent vat. Since the slurry has Since the choice of powder is penetrate through the ceramic slurry cases where smoother surfaces are very thin layers (down to 25 µm) and solidified by light. a relatively high viscosity of between linked to the final properties of to the equivalent of at least one required. then the physical part is built up by Unlike most AM technologies, 1 and 100 Pas, a recoating system the ceramic part, LCM follows the layer thickness, the usage of dark Fig. 11 shows a graphical target- adding the individual cross-sections LCM builds the part upside down. is needed to spread a fresh layer of approach of adapting the technology materials is challenging. However, actual comparison between a LCM in a layer-by-layer manner. LCM is This method significantly reduces the slurry before each curing sequence. to a given powder and not vice-versa. it has already been shown at Vienna produced structure after debinding a slurry-based process, where the required amount of slurry. Moreover, The recoating system consists of a This means that the technology University of Technology that silicon and sintering and its underlying CAD can process almost any sinterable carbide can be processed by LCM design, conducted at the Technical powder. So far, many different [3]. Further work is currently being University of Kosice’s, Department powders have been processed using undertaken by Lithoz to expand the of Biomedical Engineering and LCM, with particle sizes ranging range of processable materials for Measurement in Slovakia. The outer from approximately from 100 nm LCM to additional oxides as well as dimensions of the test geometry to 100 µm. There is no definite to nitrides and carbides. were 13 mm x 13 mm x 10 mm in the limitation for the particle size of Alumina is one of the most sintered state. As can be seen from the powder used, but, as in any widespread materials in the ceramic this measurement, any point on the other slurry-based process, nano- industry and Lithoz has focussed in part showed a deviation of less than powders are much more difficult to recent years on this material. With 60 µm from the target dimensions. On disperse and the viscosity rises with its LithaLox HP 500, Lithoz provides the one hand, this clearly shows the increasing surface area. Thus, the a high purity alumina with good highly isotropic shrinkage behaviour required minimum solids content material properties. Densities of of the LCM produced part and, on the has to be met. At the upper end, over 3.96 g/cm³ (99.4 % TD) can be other hand, it also confirms that it is the layer thickness is the limiting achieved, resulting in a four point possible to compensate for shrinkage factor as the particle size should not bending strength of around 430 MPa during sintering without sacrificing exceed the thickness of an individual with a Weibull-modulus of 11. precision or dimensional accuracy in layer. The microstructure of an alumina the final part. Fig. 10 Microstructure of alumina processed with the LCM technology at different magnifications

References

[1] Kein Herz aus Stein: Keramische POWDERMET2015: Herzpumpe dank innovativem 3D-Druckverfahren, www.tuwien. ac.at/aktuelles/news_detail/ Advances in MIM materials article/7583/) [2] Schwentenwein,M et Homa, J, and processing highlighted in Additive Manufacturing of Dense Alumina Ceramics, International Journal of Applied Ceramics San Diego Technology, Vol 12, No 1, p 1-7 [3] Gmeiner, R et al., Stereolithographic Ceramic Manufacturing of High Strength The POWDERMET2015 Conference and Exhibition, which took place in Bioactive Glass, International Journal San Deigo, California, from May 17-20, 2015, continues to encourage of Applied Ceramic Technology, Vol Fig. 12 Ceramic casting cores made by LCM 12, No 1, p 38–45 MIM producers, industry suppliers and researchers from around the world to share their latest research and developments. In this exclusive

Acknowledgements report for PIM International Dr David Whittaker reviews papers from Conclusion be seen as a new forming method, Japan, India, Germany, the UK and the USA that reflect a number of key which opens up new opportunities The authors would like to thank AM today offers the ceramics areas for MIM process enhancement and industry growth. and opportunities. It is not a substi- Teodor Toth, Radovan Hudak, Darina industry a new tool for prototyping tute for traditional forming processes, Glittova and Jozef Zivcak from the and for developing new applications. but rather an addition to the industry Technical University of Kosice, With LCM, it is possible to achieve to open up new markets. Faculty of Mechanical Engineering, the same, or at least very similar, One such promising market is Department of Biomedical properties to conventional ceramic ceramic casting cores for turbines Engineering and Measurement for manufacturing technologies. This made from superalloys. The cooling the CT measurements. The financial point is inevitably a basic condition channels designed into these support of this work by the Austrian for the final acceptance of AM as a products are becoming ever more Research Promotion Agency (FFG) forming technology for structural complex and Ceramic Injection under the project number 849275 is There was much to interest devotees Toshiko Osada, Kentaro Kudo and because this alloy has poor work- parts. If the necessary tolerances and Moulding is reaching its limits. There kindly acknowledged. of Metal Injection Moulding at the Fujio Tsumori (Kyushu University, ability in conventional processing. surface qualities are not reached, is a high probability that some special POWDERMET2015 conference, with Japan) addressed the improvement of However, previous work by this grinding and polishing can be applied core designs will be made in the four technical sessions specifically the fatigue strength of titanium alloy group had revealed a potential to achieve the desired values. future only by AM. Other products in Further resources dedicated to MIM and a number of (Ti-6Al-4V) compacts processed by ‘Achilles’s heel’ for MIM Ti-6Al-4V, in AM is not a threat to the ceramics mechanical or biomedical engineering Videos showing the LCM process are relevant papers in other sessions. MIM [1]. that it delivers low fatigue strength industry, but much more an will also emerge. Current limitations available to view at www.lithoz.com/ In the exhibit hall, the industry was MIM processing is potentially compared with the wrought counter- opportunity to move into new fields are only in our minds and we should en/news/press/lithoz-videos/ also well represented with a host of advantageous for Ti-6Al-4V, not least part. and develop new applications. AM has tear down these barriers to reach materials and technology suppliers a huge potential to become a ‘game new markets. AM could provide an from around the world participating. changer’ for the industry with its new enormous opportunity for the ceramic As reported elsewhere in this issue, freedom in design. This new way of industry to extend its business. It just MIM also scored a large number designing has to be fully understood remains for the application of AM to of successes in the Metal Powder and it will take some years to convey be developed. the new limits in design to the Industries Federation’s 2015 Design industry. Therefore, it is very impor- Excellence awards. tant to start working with AM as this Authors is the easiest way of learning. Dr Johannes Homa and Improving the fatigue AM should not be compared with Dr Martin Schwentenwein strength of MIM titanium conventional forming technologies alloys in terms of cost and performance, Lithoz GmbH because AM is not intended to replace Mollardgasse 85a/2/64-69 A number of technical papers traditional forming technologies. AM 1060 Vienna related to material developments in is a new forming technology and it will Austria particular MIM-processed alloy types, push the current limits of manufac- Tel: +43 1 9346612 201 notably titanium alloys, stainless turing, thus allowing the ceramic Email: [email protected] steels and high speed steels. A paper industry to move forward. AM should www.lithoz.com by Hideshi Miura, Choe Jungho, Fig. 1 POWDERMET2015 took place in San Diego, USA

The reported study involved the Sll# Powder Fe Ni Cr Mo Co Mn Nb Si Cu C N O S W P addition of small amounts of boron to the MIM alloy composition, using 1 SS 174PH Bal 4.1 16.8 0.11 nil 0.70 0.2 0.67 4.2 0.026 0.10 0.13 0.004 nil 0.024 a TiB powder. The Ti-6Al-4V powder 2 2 SS 316 Bal 11.2 17.5 2.4 nil 1.19 nil 0.59 nil 0.02 0.009 nil 0.014 used was spherical and was classified to be less than 45 µm diameter with a 3 SS 420 Bal 0.3 13.5 0.5 nil 0.8 nil 0.75 nil 0.6 nil 0.35 0.03 nil 0.03 mean diameter of 31.43 µm, while the 4 Nitronic 60 Bal 8.6 17.2 nil nil 7.4 nil 4.5 nil 0.018 0.16 0.09 0.006 nil 0.01 TiB2 addition was much finer with a mean diameter of 1.36 µm. 5 1.4882 Bal 4.1 21.5 nil nil 9.3 2.2 0.17 nil 0.55 0.42 nil nil 1.3 nil Powder mixes containing 0, 0.3 6 440 C Bal 0.12 17 0.64 nil 0.74 nil 0.64 nil 1.11 nil nil 0.008 nil 0.016 and 0.6% boron were processed to MIM feedstock, moulded into tensile 7 Ni free SS Bal 0.12 17 3.3 nil 10.4 nil 0.89 nil 0.018 0.32 nil nil nil nil Fig. 2 Grain sizes measured by EBSD [1] and fatigue test-pieces and debound Table 1 Chemical composition of Stainless steel (SS) powders chosen in the study [2] and sintered. The as-sintered tensile and fatigue properties were then the 0.06 % B samples was 382 MPa. However, no effect of MIM components. Material characteristics such as sintered assessed. grain refinement was seen for the high stress, low cycle density, surface porosity and hardness were analysed and Fig. 2 show that the prior β grain tests. correlated to the mirror finished products. sizes of boron added compacts, A data point from a wrought Ti-6Al-4V sample, mill The levels of porosity in the sintered products measured using electron back scat- annealed and with an average grain size of 70 μm, was were analysed for all the materials chosen using light tering diffraction (EBSD), were finer included in Fig. 5 for comparison. This fatigue test was, microscopy. The surface of the watch case product was than that of boron free compacts. however, carried in a pull-pull mode at an R = 0.1 in mounted on an acrylic material and polished on the surface However, in the case of the 0.03 % the load control mode and with a frequency of 10 Hz. It of the component to obtain a uniform surface without any boron addition, some of the prior β is therefore highly questionable whether such a direct roughness. The as-polished acrylic metallographic mount grain sizes remained unaffected and comparison of properties is valid. Notwithstanding this, was analysed to study the percentage surface porosity on a a few prior large β grains, which were however, the authors concluded that the study had shown selected area of the MIM watchcase, as shown in Fig. 6. almost the same size as in the boron that boron addition increased the fatigue limit of MIM All of the MIM sintered watch case products were free samples, were still present. This Ti-6Al-4V, though the fatigue limit was still lower than that polished to understand the mirror finish with the materials. Fig. 3 Optical micrograph of TiB in 0.6%B compacts [1] resulted in an increase in the average for the wrought alloy. Polishing consisted of lapping on the surface of the grain size of the 0.03% B sample. sintered component just before polishing as a preliminary Boron was shown to be present as step, the lapping process being performed in different titanium boride in the sintered parts, MIM of stainless steels for applications with steps depending on the roughness or burrs present on with the boride particles pinning the critical surface finishing requirements the sintered metal product (normally two or three stages) grain boundaries and preventing using different grit sizes ranging from 100 to 600 grit size. grain growth. Fig. 3 points out these A paper by B N Mukund, T S Shivashankar and M Sachin After lapping of the parts, the next step involved rough titanium boride particles using arrows (Indo-US MIM tec. Pvt. Ltd., India) turned attention to polishing in two different stages. The polishing was carried in an optical micrograph. The titanium stainless steels and reported on MIM of stainless steels for out using a cotton wheel with a rough buffing compound boride particles have a sharp needle surface finishing applications [2]. like shape with length under 10 μm. The recent high growth rate in consumer electronic Fig. 4 shows the tensile test applications with the growth of smartphones, smart- results. In all cases, the tensile watches, wearable electronic devices, laptops and tablets strength is over 850 MPa. The tensile has demonstrated the advantage of MIM technology in Fig. 4 Tensile test results [1] strength seems not to have been manufacturing highly complex designed parts with tight affected by the grain size or the boron tolerances at competitive price compared to alternative content. The ASTM B348 Gr5 standard manufacturing technologies. Most of these applications for wrought Ti-6Al-4V quotes a value in consumer electronic devices also require a high gloss of 895 MPa for tensile strength and a metallic texture or mirror finish and appropriate strength minimum elongation of 10%. With the for protection. exception of the tensile strength for In the reported research work, MIM stainless steel the 0.03% B sample, all the require- materials such as 17-4PH, 316, 420, Nitronic 60, 1.4882, ments of the ASTM standard were 440C and nickel-free stainless steels were used to therefore met. evaluate their polishing and lustre properties. The powders The fatigue tests clearly showed used were made by gas atomisation and their chemical the effect of the grain size refinement. compositions were as shown in Table 1. Fig. 5 shows the results of rotational Components were injection moulded in a machine bending fatigue tests. The fatigue with a hardened screw and barrel and the parts were limit for the boron free samples subsequently sintered in an argon atmosphere. The Fig. 6 Selected area on the surface of the MIM watchcase was 291 MPa, that for the 0.03 % B sintered components were polished with the aim of component chosen to analyse and interpret % surface Fig. 5 Rotating bend fatigue test results [1] samples was 345 MPa and that for obtaining a consistent mirror finish on the surface of the porosity [2]

In the present study, the materials, Polishability Rating Lustre rating Experimental Polishability Lustre which had the least level of or S1# Material Hardness Potential Applications rating rating Rating 1: Least number of pores / No pores Rating 1: Bright finish absence of surface porosity without (Average), HV1 any surface defects, were reported Rating 2: Medium number of pores Rating 2: Matte finish 1 SS 174PH 1 2 340.12 to be given a polishability rating 1. Consumer electronics components like cell Rating 3: More number of pores Rating 3: Dull finish Polishability and lustre level ratings 2 SS 316 1 1 145.20 phones, smart watches, wearable devices & were given on a scale of 1-3 as aesthetic applications Table 2 Polishability and lustre ratings [2] 3 Ni free SS 2 1 292.90 defined in Table 2. The reported study evaluated the polishability rating 4 SS 420 2 2 390.41 Applications which need moderate wear by examining the intensity of pores resistance and strength which includes hand % Surface Porosity on Polishability Lustre rating 5 Nitronic 60 3 2 186.73 the MIM on the surface of the polished MIM tools, power tool and medical instrumentation rating after S1# Material sintered product after mirror mirror product visually. The lustre rating 6 1.4882 3 3 342.02 analyzed through High wear resistant applications where polishing polishing was also quoted, based on visual light microscope cosmetic requirements are not mandatory observations and the materials / 7 440 C 1 3 550.57 1 SS 174PH 0.50 1 2 products, which had a bright finish, Table 4 Hardness of the MIM watch case product with different materials and the potential applications [2] were reported to be given lustre 2 SS 316 0.38 1 1 rating 1. and the results were correlated to the highest polishability rating (Rating 3 SS 420 1.16 2 2 Table 3 shows the after-polishing MIM M2 high speed steel % surface porosity measured through level 1). Hence, it can be concluded observations of the MIM watch produced by pre-alloy and 4 Nitronic 60 2.05 3 2 light microscopy, as reported in Fig. 7. that polishability is independent of case sintered product in terms of master alloy routes As can be noted from Fig. 7, there hardness. 5 1.4882 1.43 3 3 polishability and lustre level rating. It was a positive correlation between The overall conclusions drawn A paper by Keith Murray, Martin was observed that 17-4PH, 316 and 6 440 C 0.39 1 3 the polishability rating and the % from the study were that 17-4PH, Kearns, Mary-Kate Johnston and 440C were found to have the least / surface porosity measured, which 316 and 440 C were found to be the Paul Davies (Sandvik Osprey, UK) 7 Ni free SS 1.95 2 1 no pores on the surface (Polishability indicated that the porous surface best in terms of polishability rating, and Viacheslav Ryabinin and Erainy rating level 1) of the mirror polished Table 3 Polishability and lustre level rating on the MIM watch case products on the polished MIM product is due because sintered density was found to Gonzalez (TCK, Dominican Republic) sample in comparison to the other after mirror polishing [2] to the pores present in the sintered be greater than 99% of the theoretical considered the sintering and materials. This could be due to the product prior to the mirror polishing density. However 420, Ni free properties of MIM M2 high speed lower porosity achieved after sintering process. Hence, the sintered product stainless steel, 1.4882 and Nitronic 60 steel produced by pre-alloy and (or higher density) as shown. Nitronic should have the least level or no were found to have density lower than master alloy routes [3]. used to obtain a good lustre and the polished product was rotated at 60 and alloy 1.4882 were found to have pores on the surface to obtain a highly 99% of the theoretical density and The reported study assessed gas mirror finish. The polished compo- different angles in order to check for the highest number of pores, whereas aesthetic mirror-finished surface hence may need some post-sintering atomised pre-alloyed M2 powders in nents were ultrasonically cleaned to defects, if any, including the surface 420 and Ni free stainless steel were after polishing. operation, such as HIPping, to two different particle size fractions remove the buffed compound during porosity. The distance between the found to have a medium number of As shown in Table 3, 316 and Ni improve density. (90% -22 µm and 80% -22 µm) and polishing. eyes and product was maintained pores. free stainless steel were found to It was found that the material compared sintering response and The mirror polishing inspection between 30-40 cm. Inspection time The porosity levels observed after have excellent lustre in comparison which had a better polishability rating achieved mechanical properties with was carried out using a natural white was fixed for 10 seconds and, if no mirror polishing were given ratings to the other materials evaluated. with least or no porosity need not those of high and low carbon M2 light providing 1500 + / - 200 lux at defects were observed, the product from level 1 to level 3 depending on As can be seen in Fig. 8, there is necessarily show good lustre after master alloy grades mixed at a ratio the working level. The surface of was acceptable. the number of pores visually observed no correlation found between the polishing and vice versa, as both are of 1:2 with fine carbonyl iron powders lustre rating and the % surface independent characteristics of the of two different carbon contents porosity measured, which indicates material. An example of this was (0.81 and 0.005 wt%). The chemical that the lustre on the polished MIM 440C, where the lustre was not good. analyses of the powders used are product is no longer due to the pores It is evident from the reported study shown in Table 5. present in the sintered product prior that 316 is the most suitable material It was found that sintering to the mirror polishing process. to provide a combination of an the 90% -22 µm gas atomised The lustre is mainly dependent on excellent mirror finish with the best pre-alloyed powder product at the chemical composition of the lustre on MIM components. However, 1220°C was effective in achieving full material, especially the presence of 17-4PH and Ni free stainless density, whereas the coarser 80% molybdenum, which is beneficial for steels can also be used where the -22 µm powder fraction required lustre. application demands higher hardness a temperature of 1240°C for full Table 4 reports the hardness of the than 316 can provide, along with the densification (Fig. 9). Microstructural MIM sintered product measured for best mirror finish and lustre in MIM coarsening of pre-alloyed M2 the various stainless steel materials products. was observed with a sintering chosen. As shown in this table, 440 Further studies are planned to temperature of 1240°C (Fig. 10), with C was found to have the highest evaluate the polishability and lustre the observation of grain coarsening hardness whereas 316 was found rating of Ni free stainless steel, and the precipitation of coarse grain Fig. 7 Relationship between polishability rating and % Fig. 8 Relationship between lustre rating and % surface to have the lowest hardness. It was 420, Nitronic 60 and 1.4882 alloying boundary carbides, associated with surface porosity measured through light microscope porosity showing no correlation [2] also observed that both 440C and compositions after performing precipitate-free zones adjacent to showing positive correlation [2] 316 materials were found to have the HIPping on the sintered products. grain boundaries.

Alloy Fe Cr W Mo V Mn Si N C O %C (final part) %C %O %C %O Alloy, Lot # (M2) (M2) (CIP) (CIP) 1220° 1240° 1250° M2 PA 031912-1 Bal 4.1 6.1 4.8 1.9 0.39 0.31 0.04 0.84 0.074 ΔC C C C M2 PA 121514-1 Bal 4.0 6.0 4.6 1.9 0.28 0.25 N.A. 0.83 N.A. M2 PA, 031912-1, 90%-22 0.84 0.074 - - 0.82 0.81 0.81 -0.03 M2 MA 121514-2 Bal 13.3 17.9 15.3 5.8 1.0 1.2 N.A. 2.9 N.A. M2 PA, 121514-1, 80%-22 0.83 N.A. - - 0.80 0.79 0.79 -0.04 M2 MA low C 121514-3 Bal 13.3 18.4 15.0 6.1 1.0 0.9 N.A. 1.14 N.A. M2 MA, 121514-2 2.90 N.A. 0.02 0.43 - 0.89 0.90 -0.07 Sintez HC 669 Bal ------0.81 0.78 0.25 M2 MA low C, 121514-3 1.14 N.A. 0.78 0.25 - 0.85 0.87 -0.04

Sintez BC 477 Bal ------0.005 0.02 0.43 ΔC in PA is relatively small & increases with rising temperature P, S both

Table 5 Chemical analyses of the powders used in the study [3] Table 6 Changes in carbon content during sintering [3]

The higher carbon master alloy variant, a 90% - 12 µm product would and carbonyl iron powder mixture be required with consequent cost required a sintering temperature penalties. of 1240°C for full densification, but the achieved microstructures were inhomogeneous, whereas the low The influence of hydrogen carbon master alloy and carbonyl partial pressure on the iron powder mixture showed lower debinding and sintering density at this sintering temperature response of MIM stainless (Fig. 11), because of a higher solidus steels temperature. In all cases, measured carbon losses in sintering were A suite of papers at POWDERMET2015 modest and were predictable on the considered the optimisation of a Fig. 9 Sintering response of products from the two pre-alloyed M2 particle size basis of initial carbon and oxygen range of processing parameters in Fig. 12 Results of drape tests for M2 master alloy route materials – deflection fractions [3] levels (Table 6). MIM. The paper by Satyajit Banerjee vs. overhang [3] The highest hardness and strength (DSH Technologies LLC, USA) and levels were achieved in the sintered Claus Joens (Elnik Systems LLC, USA) Sintering 0.2%PS UTS M2 source %El HRC condition with the pre-alloyed variants assessed the influence of hydrogen Temp, oC (MPa) (MPa) (see Table 7). Work is currently partial pressure on the debinding and 1220 PA 978 1499 - 57.5 ongoing to determine whether a sintering response of MIM stainless solutionising and tempering heat steels [4]. PA 1040 1418 - 57.5 treatment of the M2 produced through The debinding and sintering of 1240 MA 988 1377 0.5 55 the master alloy route can lead to MIM parts under a 100% hydrogen homogenised microstructures and atmosphere has been reported, MA LC 776 1329 1 54 enhanced mechanical properties. but in furnaces that can only run at MA 969 1141 1.5 56 On the other hand, the master 15 mbar partial pressure i.e. below 1250 MA LC 1106 1386 0.8 55 alloy route offers significant benefits the lower explosion limit for hydrogen. Fig. 10 Microstructure of pre-alloyed M2 materials sintered at 1250°C [3] in terms of sintering distortion levels, Because such furnaces do not need Table 7 As sintered mechanical properties for the M2 material variants [3] with distortion being observed to be to incorporate safeguards to meet much lower than with the pre-alloyed NFPA safety requirements, they are steel feedstocks were therefore consistently better than the typical material route. All of the pre-alloyed of relatively low cost compared with injection moulded into ISO tensile values from the MPIF 35 specification. material samples (80% -22 µm and standard hydrogen furnaces. Standard bars and then debound and sintered Corrosion testing was also carried 90% -22 µm) failed cantilever and furnaces, with all of the relevant in hydrogen at either 15 or 400 mbar. out by immersing the tensile bars slump tests. The deflections observed safeguards, would, on the other hand, The achieved as-sintered tensile in a 1% saline solution at 62°C for in cantilever tests on M2 master alloy operate typically at partial pressures properties for 17-4PH are shown in 5 days. The 1% saline corresponds samples were found to be in line of 400 and/or 800 mbar. Table 8 and are compared with the to the saline content of most body with the expectations of beam theory The question addressed in this values quoted for this grade in MPIF fluids, whereas every 5°C above body (Fig. 12). The master alloy mixtures, paper was whether the extra cost Standard 35 (Table 9). It can be seen temperature (37°C) corresponds because of the addition of the finer involved in debinding and sintering that the values for the 15 mbar runs to a doubling effect of the time of carbonyl iron powders, had a particle in hydrogen at a partial pressure of were above the minimum property immersion in the test. The parts were size distribution more equivalent to a 400 mbar as opposed to 15 mbar is values specified in MPIF 35, but immersed for 5 days at 62°C; this 90% -12 µm pre-alloyed powder and justified in terms of improved proper- not better than the typical values would correspond to the equivalent of so it is anticipated that, to achieve ties and performance in the final MIM mentioned. The values for the immersion for 5 x 25 (i.e. 160 days) at Fig. 11 Effect of temperature on sintering of M2 master alloy route materials [3] equivalent rigidity in a pre-alloyed product. 17-4 PH and 316L stainless 400 mbar sintered products were body temperature.

chromium and iron. The comparative 0.2% TS % % Atmosphere Density YS % Cr % C assessment of inclusions in parts (MPa) Elong. Cu (MPa) sintered at 400 mbar (Fig. 15) did show some oxides but the oxides seen 15 mbar (A/S) 7.69 875 687 78 16.25 3.45 0.007 in this analysis had a peak intensity H900 1196 1067 7.3 of more than 200 times weaker than those seen in Fig. 14. 400 mbar (A/S) 7.68 995 778 4.5 16.21 4.04 0.013 SEM/EDXA assessments were also carried out on a corroded and cracked H900 1266 1104 6.1 sample that had been debound and Table 8 Tensile properties of as-sintered 17-4 PH [4] sintered at 15 mbar. The SEM micrograph in Fig. 16 shows that bending had caused the part to fracture further along grain boundaries. An Density TS (MPa) YS (MPa) % Elong. EDAX analysis of the region showed chlorides and sodium from the saline, Min. A/S 7.5 790 650 4 Fig. 14 EDXA of the inset scanning electron micrograph of inclusions seen in a 17-4 PH part sintered at 15 mbar [4] oxygen and silicon from the silica H900 1070 970 4 inclusions, calcium, probably from the tap water, and chromium and Typical A/S 7.5 900 730 6 iron. This picture probably verifies the H900 1190 1090 6 theory that the presence of the silica type inclusions in the presence of the Table 9 MPIF Standard 35 values for as-sintered 17-4 PH [4] chloride ions results in the formation of galvanic cells that enhance the In the case of both stainless steel and were found to relate to differ- rate of corrosion of the alloy sintered alloys, the parts sintered at 400 mbar ences in the populations of inclusions at 15 mbar. When the same alloy is showed no corrosion and a much in sintered parts processed at the sintered at 400 mbar, there are no better corrosion resistance. For both two different partial pressures. The oxide inclusions to form the galvanic alloys, the parts sintered at 15 mbar scanning electron micrograph in Fig. cells that enhance the corrosion rate. started showing signs of corrosion 14 shows a spheroidal inclusion seen Overall, the authors concluded after one day. In the case of the 15 in a part sintered at 15 mbar. The that, although the achieved tensile mbar corrosion samples one of the fracture itself is a mixture of brittle properties do not show a large differ- bars showed corrosion within the first and ductile fractures. The energy ence between sintering at 15 mbar Fig. 15 EDXA of the inset scanning electron micrograph of inclusions seen in a 17-4 PH part sintered at 400 mbar [4] day and was removed after 24 hours. dispersive X-ray analysis (EDXA) of the and 400 mbar, the overall effect of The underlying reasons for inclusion shows it to comprise mainly sintering at 400 mbar is a superior these differences in properties and silicon and oxygen suggesting the product with optimum corrosion performance were then investigated presence of silica with other oxides of resistance and optimum properties comparable to wrought products.

Controlling furnace Carbon Potential in continuous MIM production

A paper by Akin Malas (Linde AG, Germany), Eric Will (Linde LLC, USA) and Soren Wiburg (AGA Gas AB, Sweden) addressed the cost savings and quality improvement that can accrue from enhanced Carbon Potential (CP) control in the sintering Fig. 16 EDXA of the inset corrosion sample after 1 day, 15 mbar, cracked area [4] furnace atmosphere [5]. During the sintering, especially varying carbon content of the parts a new way of monitoring and The system has been deployed in of ferrous materials, the Carbon coming into the furnace is addressed correcting carbon control issues with the control of sintering of both die Potential of the atmosphere is a and corrected/adjusted for with a technology called Sinterflex®. This pressed PM compacts and MIM variable that needs to be accurately on-line monitoring and control system incorporates an oxygen probe products. monitored and controlled to correct feedback. as well as a carbon monoxide and Carbon control is a challenging for carburisation and decarburisation To achieve these objectives, Linde hydrogen analyser for proper carbon task in MIM sintering processes and Fig. 13 316L parts sintered at 15 mbar after 5 days in 1% saline solution [4] of the parts being processed. The has developed and commercialised potential determination and control. is currently most commonly achieved

in the matrix left after de-binding is the Sinterflex system, the standard post-processing”. A fraction of this protected in a neutral atmosphere. deviation is approximately 0.15%, tier is purposely processed to end The parts then enter the cooling zone while with the Sinterflex system the in this category, because it needs where there is still a slight carbon standard deviation is reduced to further heat treatment by either containing atmosphere present. This approximately 0.03%. nitriding or other post-processes allows a final protection of the carbon Sinterflex ACS also allowed and this is therefore described as layer from the surface. Megamet to keep the hydrogen flows planned post-processing. The other As a means of quantifying the at fixed values, leading to simpli- portion of this group is “workable” benefits of deploying the system fied operation as well as reduced due to the carburisation potential in in MIM sintering, the results of operator interference with produc- the atmosphere causing this section collaborative trials with Megamet tion, and to reduce hydrogen flows, to be out of the “in spec” category, Solid Metals (now Ruger Precision resulting in lower atmosphere costs. but not far enough from specification Metals, LLC) were then discussed. The other metric that has been where the part is completely in the Since December 2013, tests have studied in deeming the project a “unusable” category. These parts can been running to investigate carbon success has been the impact on undergo unplanned post-processing percentage, hydrogen percentage, rejection and reprocessing statistics. that will move the parts into the “in mV of oxygen, as well as other Ultimately being able to control the spec” category, therefore resulting characteristics that are monitored atmosphere should result in less in experiencing unplanned post- Fig. 17 Comparison of current practice versus SINTERFLEX Atmosphere Control System in the MIM sintering process [5] and recorded. Homogeneity and post processing and less rejected processing costs. consistency in the furnace atmos- parts. Megamet characterised its Fig. 19 shows a comparison of by prediction of process conditions Fig. 17 shows a graph demon- parts) causing a source for carbon in phere are pivotal to the success rejection statistics in three catego- results over a two month period in almost all of the companies strating the current practice in green the atmosphere and hence providing of MIM manufacturing. In order to ries: based on the categorisation above. operating a continuous MIM furnace. versus an operation handled by the a protection for decarburising. characterise how Sinterflex ACS By using Sinterflex technology, the The control of the furnace process Sinterflex Atmosphere Control System However, the measurements show affects these attributes within the In spec number of unusable parts decreased is carried out only by controlling in red. Existing practice, as shown by that the atmosphere during this process, the part rejection statistics In spec means that the part is within by 15%, resulting in significant the input gases and predicting the the green line, is to predict the total time is extremely decarburising and and standard deviation of carbon specification and needs no more post savings. changes based on the final carbon decarburisation of the 4.8% carbon therefore the de-binding continues content within parts over periods of processing to adhere to the customer As the Sinterflex system continues results. Therefore, when part analysis in the part down to the specification until the sintering is complete, where time have been recorded. Results stipulations. to run, the testing process becomes results come from the quality control during the whole sintering process the parts reach their final carbon have been classified into three less necessary because the carbon laboratory, the parts either pass the involving all zones of the furnace. The levels. Because of this uncontrolled categories; parts in specification Unusable results are more reliable. Instead of requirements or are rejected based brown part starts with 4.8% carbon decarburisation, it is always difficult immediately after sintering, workable Unusable implies that the parts are testing parts every three hours, it has on best guesses, leading to high and enters the thermal de-binding to predict the final results as well as parts that could be remediated with rejected and officially scrapped. become acceptable to extend testing scrap rates. These scrap rates, in zone, where the binder is supposed the variation of the carbon from one additional processing and parts that of parts to once or twice a day. In mainly continuous operations, can to be removed from the MIM mass. production run to another due to an needed to be scrapped due to the Workable addition to the favourable reduction be up to 25 percent in cases where However, the carbon will be carried unstable furnace atmosphere. severe difference in carbon between Workable indicates a more in unusable parts, the volume of complex alloys are processed, such as through to the high heat zone On the other hand, the Sinterflex specification and actual final carbon complicated aggregation of parts that parts in specification increased by stainless steels. (probably in the outer sections of the Atmosphere Control System (ACS) content after processing. can further sectioned into “planned 30%. This was effectively double the does not rely on the availability of the Carbon content in the absence post-processing” and “un-planned amount of parts that were within of monitoring and control can often binders (hydrocarbons) as the source )LJXUH5DWLRRISDUWVZLWKLQDQGRXWRIVSHFLÀFDWLRQRYHUWZRPRQWKSHULRG of carbon in the high heat zone. The differ by +/- 0.3% on just one boat. 7LPHZLWKRXW6,17(5)/(; 7LPHZLWK6,17(5)/(; Sinterflex system starts with the These differences can result in complete removal of the binders in manufacturers having to do multiple the pre-heat / de-binding zone of the post treatments. In Fig. 18, the carbon furnace, as shown in the red line. content over a one day period of 3DUWV Therefore, the brown body no production is shown in conjunction LQ with its specified upper and lower longer contains any binders in the high heat zone. The system creates limit requirements. Both graphs are a very decarburising atmosphere to based on the same part constructed make sure the binder is removed at of the same material. There is a this point. However, the high heat visible difference between the two zone is already very low in carbon, graphs, as the part when controlled at approximately 0.05%C potential. with the Sinterflex ACS is continu- Therefore, the second section of ously processed within specifications the Sinterflex system starts to for the entire time and has less vari- create a neutral atmosphere, as in ance in carbon content trends. This most industrial hardening furnaces can be further proven by the standard ,QVSHF:RUNDEOH 8QXVDEOH regardless of the final part require- deviation of the carbon content in the Fig. 18 Carbon content of sintered parts over an 8-hour period [5] ment, to make sure that the carbon parts throughout that day. Without Fig. 19 Ratio of parts within and out of specification over two-month period [5]

course, the choice of robot. This is Conveyors are commonplace and Cycle Time Productivity per Week Quality Yield per Week by % of Loss dependent on the task to be under- can be used as a simple transfer unit Cavitation = 2 40 hrs per week Single Molder taken. Available robot types divide Cavitation = 2 40 hrs per week Single Molder or a complicated indexing system between the “dumb” and “smart” Cycle Time = 25 Sec Cycle Time WK 1 WK 2 WK 3 WK 4 1 Yr that can move multiple parts on tiles categories. or shelves. % loss WK 1 WK 2 WK 2 WK 4 1 Yr 25 sec 11520 23040 34560 46080 599040 Dumb robots are non-program- Another method of moving parts 24 sec 12000 24000 36000 48000 624000 mable. They are simple in nature, 25 8640 17280 25920 34560 449280 after robotic placement is the use of lack complicated programming and Shuttle or Index Tables. These are 15 9792 19584 29376 39168 509184 23 sec 12521 25042 27563 50084 651092 could be mechanically operated. An generally more complicated than 22 sec 13090 26180 39270 52360 680680 example would be a 2-axis robot that 10 10368 20736 31104 41472 539136 a conveyor system. The robot can would reach into a mould. The parts place multiple parts onto a setter. 21 sec 13714 27428 41142 54856 713128 would drop into a small cup and, upon 5 10944 21888 32832 43776 569088 Once that setter is full, the table will retraction, would drop the parts onto 20 sec 14400 28800 43200 57600 748800 2 11290 22579 33869 45158 587059 index. The robot can now place parts a conveyor. on a secondary setter that was set in Table 10 Comparison of parts produced at various cycle times [6] Smart robots are programmable, Table 11 Value of product yielded based on % quality loss [6] place prior to the first becoming full. and (depending on the style) can be The first setter can then be placed specification before Sinterflex was Robotics for improved very capable of complex movements. as component assembly or replacing in the electronic and food industries. on a cart to transfer to the next implemented. quality and productivity They can range from 3 to 6 axis and parts from one location to another. Like the SCARA robots, Delta robots operation or an inspection station. When parts are out of specification, host a variety of end of arms (EOAs) In a moulding environment, SCARA may have limited application in MIM. MIM inspection systems are visual a decision is made as to whether Finally, a paper by Jonathan Newman to accomplish a wide variety of tasks. robots may have limited application. Secondary placement that requires in nature (camera systems). The the part can be post processed back (Kinetics Dynacast Inc., USA) consid- This category of robots could be any However, these applications could aid precision may be the key to this capabilities of these systems vary into specification by heat treatment. ered the impact of robotic integration of the following: in inspection, placement or assembly, robot. and can look for visual defects in Sometimes, parts can undergo this on the improvement of quality and depending on the operation. Next, the End of Arms (EOAs) parts or take actual measurements post processing and still not be in productivity in MIM [6]. This paper Gantry robots are chosen. EOAs give the robot a on parts. In some cases, this type specification. The quantity of parts underlined the benefits of robotic Gantry robots are 3 axis (X, Y, and Z) Delta robots purpose. In the MIM context, the EOA of system could be capable of both categorised as ‘workable parts’ also integration in responding to the chal- robots and travel in linear motions. Delta robots resemble a spider with is used to pick parts from the tool in tasks. decreased by 15%, demonstrating lenge of simultaneously improving Many are attached to the top of their multiple legs and operate in the moulder. After the part is picked, In constructing a robotic cell, that the Sinterflex system has both productivity and product quality. moulders, but larger ones can span a circular/domed work area. They it is placed directly on a conveyor for safety considerations are very tempered this ambiguity in the post Robots have the advantage of the machines for wider applications. are extremely accurate and capable human placement, into a basket for important. Some robots can be processing category. being predictable. They can take These robots can also be given a wrist of precise movements. These dewaxing or directly onto a setter for programmed for pressure (touch), Finally, the ability of the Sinterflex repeatable tasks and perform them to give them rotational movement capabilities make them widely used further processing. but this is generally not done in a unit to monitor, record and ultimately time and again with extreme accuracy at the EOA. These can be ideal for adjust the process parameters of and speed. One of their biggest pulling parts from a mould and then the sintering operation has identified advantages is that they remove the placing them on a conveyor or setter. other issues from a product and variation caused by humans that With an articulating wrist, they can atmosphere standpoint that were not can plague manufacturing in quality be capable of even more complex readily apparent prior to installing control and productivity. Because of placement or of presenting parts to Sign-up for our metal the unit. By tracking the pre-heat this, they can reduce lag time that an inspection system. section dew point, hot zone carbon can rob productivity and can also Additive Manufacturing monoxide and oxygen content, as well eliminate damage that can be caused Articulated multi axis robots as hydrogen content, the Sinterflex by human handling. Articulated, multi axis robots can have e-newsletter system allowed Linde and Megamet The productivity gains that can up to 10 joints, but most commonly to gain a greater insight into the be delivered by a stable automated are 6-axis. These joints give them a complex workings of the different process are illustrated in Table 10. very wide range of motion within a zones of a continuous furnace. This table shows how a one shift work cell. They can reach multiple www.metal-am.com Troubleshooting those periods of operation can make significant gains angles with a variety of tools or EOAs process problems is greatly reduced in the number of parts produced per that enable them to perform more and the net amount of rejected parts year by reducing cycle time by just a complicated tasks in an industrial goes down accordingly. few seconds. Table 11 demonstrates environment. Whether a primary or Overall, it has been concluded how the reduction of yield loss from secondary robot, they are capable of that active control of the furnace quality issues caused by human picking, placing, presenting, handing atmosphere is important in variation can make a measurable off, assembling, etc. the optimisation of business difference throughout the year. This METAL performance, but that there are information is derived from a two SCARA robots secondary and tertiary benefits cavity tool with a cycle time of 25 SCARA robots generally have two ADDITIVE to be gained in operations from seconds from Table 10. joints (one on a fixed cylinder), and the accurate monitoring and data The starting point for the definition operate in a single plane. These lend MANUFACTURING acquisition of the Sinterflex system. of an integrated robotic system is, of themselves well to applications such

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manufacturing environment. So, if a inspection, the robot’s programming [4] Banerjee, S, et al, Debinding person is physically contacted by a allows it to drop them. Good parts will and Sintering of Stainless Steels robot, they have the potential to be move on. at 15 mbar and 400 Mbar, seriously injured or worse. To protect From the inspection station, the POWDERMET2015 Conference, May against such hazards, the robotic robot moves to placement. Company 17-20, 2015, San Diego, California, cell needs to be properly guarded. To and part requirements will determine USA help make cells safer, standards for the style of setters that are needed. [5] Malas, A, et al, Cost Savings robot guarding have been established The robot places the exact pattern and Quality Improvement by by ANSI. For MIM purposes, the that has been programmed. Because Controlling Furnace C-Potential guarding should follow a few rules. It of the robotic placement, the parts Leading to In-spec Part Carbon must encompass the entire envelope are protected from human handling Content - Further Improvements and of the robot (and possible auxiliary and setting damage. Some Good News for MIM Industry, equipment) range of motion. It Once the parts have been placed, POWDERMET2015 Conference, May must also have interlocks, whether the robot’s tasks in the cycle are 17-20, 2015, San Diego, California, mechanical or electrical, that will complete and the programmable USA shut the system down in the case of a index system takes over. When the [6] Newman, J, Robotic integration for breach. The guarding should also be system receives the signal that improved quality and productivity in a physical barrier when applicable. the placement is complete and the MIM, POWDERMET2015 Conference, The tasks to be accomplished in setter(s) are full, it moves the setter May 17-20, 2015, San Diego, integration of a robotic cell were then out of the robotic envelope. Keeping in California, USA outlined by the author. The design of line with the concept of full integra-

the cell starts with the non-operator tion, the setter can be automatically side of the machine (opposite to the placed into a cart. When the cart is control panel). The cell should be set full, the operator that started the to this side for safety reasons and process is signalled and then pulls so that the operator will not have it out the cart, installs a new cart for impeding their work. loading and transfers the full cart to The next step is the installation, the next operation. beginning with the robot and EOA. Once the set-up is complete, the Author EOAs can be changed to meet the needs of the parts being produced. Dr David Whittaker Then, the conveying system should 231 Coalway Road be set up (either an actual conveyor Wolverhampton or some type of indexing table), the WV3 7NG, UK inspection system mounted, the Tel: 01902 338498 loading components (shelves, tiles Email: [email protected] or baskets) incorporated, logistics for movement of the parts from References the moulder to the next operation [1] Miura, H et al, Improvement of considered (generally in the form Fatigue Strength for Titanium Alloy of a cart) and, finally, the guarding Compacts by MIM, POWDERMET2015 installed. Conference, May 17-20, 2015, San Now that the cell is set up, it still Diego, California, USA needs to be programmed. This is a delicate but necessary step to make [2] Mukund, B N, et al, Metal Injection sure that quality and productivity do Molding of Stainless steels for surface Download your FREE not suffer. Done correctly, production finishing speed and overall yield should Applications, POWDERMET2015 increase. Conference, May 17-20, 2015, San digital copy of the latest In operation of such an integrated Diego, California, USA cell, when the robot is holding the [3] Murray, K, et al, Sintering parts, it cycles to the inspection and Properties of MIM M2 issue at www.ipmd.net station. Here, the parts are presented High Speed Steel Produced by to a vision system and then a scale. Pre-alloy and Master Alloy Routes, These automatically determine if the POWDERMET2015 Conference, May parts are in specification to move 17-20, 2015, San Diego, California, USA POWDER on. If the parts do not pass this METALLURGY Use the QR Code to download a copy directly to your smart phone or tablet 94 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 REVIEW Events / Advertisers | contents page | news | events | advertisers’ index | email | european powder metallurgy association Events Guide Advertisers’ Index

Advanced Materials Technologies 26 Online Registration Deadline 2015 Advanced Metalworking Practices, LLC 14 Advanced Powders & Coatings 37 18 September 2015 Euromold 2015 APMA 2015 72 September 20-25, Ametek 31 Dusseldorf, Germany ARCMIM 2 www.euromold2015.com Arburg GmbH & Co. KG OBC International Euro PM2015 Atect 35 October 4-7, AT&M 20 Reims, France BASF 11 Congress & Exhibition www.epma.com Carbolite Gero 25 Carpenter Powder Products 22 Ceramitec 2015 Centorr Vacuum Industries, Inc 12 4 - 7 October 2015 October 20-23, Ceramitec 2015 52 Munich, Germany www.ceramitec.de Cremer Thermoprozessanlagen GmbH 16 Reims Congress Centre, France CTCV 40 APMA 2015 3rd International Conference on Powder Ecrimesa / Mimecrisa 36 Metallurgy in Asia Elnik Systems 29 November 8-10 eMBe Products & Services GmbH 23 Plenary Session will feature a presentation on: Kyoto, Japan Epson Atmix 9 www.apma.asia Additive and Trabecular Manufacturing for Volume Erowa 21

formnext Euromold 2015 62 Production in the Orthopaedics Industry November 17-20, Euro PM Conference (EPMA) IBC by Mr Ali Madani (CEO, Avicenne, France) Frankfurt, Germany ExOne Company 15 www.mesago.de/en/formnext FCT Anlagenbau GmbH 42 This presentation will provide examples of the main AM orthopaedic formnext 2015 51 applications and examine the challenges and opportunities for AM as a 2016 Greenlong (Qingdao Greenlong Machinery Co Ltd) 32 Indo-US MIM Tec 7 production technology in the medical device market. Inmatec 28 PM16 International Conference Jiangxi Yuean Superfine Metal Co Ltd 18 Febuary 18-20, Pune, India Kerafol 30 pmai.in/pm16 Listemann Technology AG 28 Lithoz 33 MIM2016 International Conference on Injection Moulding LÖMI GmbH 10 of Metals, Ceramics and Carbides Metal Additive Manufacturing magazine 93 March 7-9, Irvine, USA MIM 2016 71 www.mpif.org MUT Advanced Heating 4

AMPM2016 Additive Manufacturing with Powder Nabertherm 5 Metallurgy Parmatech 27 June 5–7, Phoenix Scientific Industries Ltd 39 2012 © C_Carmen Moya Credit Boston, USA PolyMIM GmbH 41 www.mpif.org/Meetings/2016/AMPM2016 Powdermet 2016 61 Powder Metallurgy Review magazine 70/95 POWDERMET2016 International Conference on Powder Renishaw plc 19 Metallurgy & Particulate Materials June 5–8, Sandvik Osprey Ltd 13 Boston, USA Silcon Plastic 26 www.mpif.org Sintex 8 TAV S.p.A. 24 World PM2016 Congress & Exhibition TempTAB 38 October 9-13, Tisoma 34 Hamburg, Germany United States Metal Powders, Inc IFC www.epma.com/world-pm2016 USD Powder GmbH 6 Winkworth Mixers 41

Developing the Powder Metallurgy Future Metallurgy Future the Powder Developing www.europm2015.com Wittmann-Battenfeld 17 @Euro_PM #EuroPM2015 96 Powder Injection Moulding International September 2015 © 2015 Inovar Communications Ltd Vol. 9 No. 3 The ArT of ProducTIon effIcIency

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