PIM International Vol 7 No 3 September 2013

in this issue Company visit: Maxon Motor Optimising mould design for PIM 50 years of PIM at Arburg

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]

Assistant Editor Sarah Scarratt Tel: +44 (0)1743 454990 Email: [email protected]

Publishing Director A drive towards increased Paul Whittaker Tel: +44 (0)1743 454992 Email: [email protected] process efficiency

Consulting Editors Welcome to the September 2013 issue of PIM International. This 96 Professor Randall M German Associate Dean of Engineering, Professor of page issue, the largest that we have published to date, comes on the Mechanical Engineering, San Diego State back of a busy summer for many of those involved in PIM. University, USA Dr Yoshiyuki Kato In June 2013 the injection moulding machine manufacturer Arburg Kato Professional Engineer Office, Yokohama, Japan organised a conference at its headquarters in Lossburg, Germany, Dr Professor Frank Petzoldt to celebrate 50 years of the company’s involvement in developing Deputy Director, Fraunhofer IFAM, Bremen, Germany technology and equipment for PIM. The event attracted more Bernard Williams than 200 international participants and covered a diverse range of Consultant, Shrewsbury, UK subjects. A common thread amongst a number of presentations Advertising was, however, the efficiency gains that can be made through the use Jon Craxford, Advertising Director of advanced mould technologies. The feature article on optimising Tel: +44 (0) 207 1939 749 mould design and function for PIM (page 39) looks more closely Fax: +44 (0) 1743 469 909 at this critical area of the process. Our report on highlights from E-mail: [email protected] Arburg’s summer PIM conference can be seen on page 57. Subscriptions Powder Injection Moulding International is published We also report on a recent visit to Maxon Motor’s PIM plant in on a quarterly basis. The annual subscription charge Germany, where a focus on high precision products has had a for four issues is £115.00 including shipping. Rates in distinct influence on the company’s unique approach to the process € and US$ are available on application. for both CIM and MIM materials (page 47). Accuracy of contents Whilst every effort has been made to ensure the In North America, MIM was again well represented at the MPIF’s accuracy of the information in this publication, annual PowderMet Conference held in Chicago, June 2013. A the publisher accepts no responsibility for errors substantial number of MIM parts were announced as winners in the or omissions or for any consequences arising MPIF’s Design Excellence Awards and the trade exhibition featured there from. Inovar Communications Ltd cannot be held responsible for views or claims expressed by a very encouraging number of technology suppliers. A diverse contributors or advertisers, which are not necessarily technical programme covered developments in both MIM materials those of the publisher. and processing (page 67).

Advertisements Three new furnace concepts from important industry suppliers are Although all advertising material is expected to conform to ethical standards, inclusion in this presented in this issue’s technical papers. These developments publication does not constitute a guarantee or reflect a real diversification in the types of furnaces being offered endorsement of the quality or value of such product to part makers, from very small continuous systems for small or of the claims made by its manufacturer. and micro sized components (page 81) to a new two unit system Reproduction, storage and usage that offers extremely clean sintering conditions (page 86), plus a Single photocopies of articles may be made for new generation of large volume batch vacuum furnaces that can personal use in accordance with national copyright bridge the gap between conventional batch vacuum furnaces and laws. Permission of the publisher and payment of continuous systems (page 91). Worldwide fees may be required for all other photocopying. All rights reserved. Except as outlined above, no Global manufacturer of nodular and spherical aluminum part of this publication may be reproduced, stored in Nick Williams powders, pre-alloyed aluminum powders, and aluminum a retrieval system, or transmitted in any form or by Managing Director and Editor premixes for PM any means, electronic, photocopying or otherwise, without prior permission of the publisher and www.ampal-inc.com www.poudres-hermillon.com copyright owner.

Design and production In the Americas Inovar Communications Ltd Cover image Supplier of carbonyl iron and atomized stainless steel powders Miniature ceramic pinion gear Printed by manufactured by Maxon Motor for the MIM and PM industries Cambrian Printers, Aberystwyth, United Kingdom United States Metal Powders, Incorporated (Photo Maxon Motor GmbH) 408 U.S. Highway 202, Flemington, New Jersey 08822 USA ISSN 1753-1497 Tel: +1 (908) 782 5454 Fax: +1 (908) 782 3489 Vol. 7, No. 3 September 2013 email: [email protected] © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 1 | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email | September 2013

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In this issue

39 Optimising mould design and function for PIM 76 LÖMI: New developments in solvent and water PIM offers many more creative possibilities than debinding systems for MIM and CIM conventional machining processes, however when quality Germany’s LÖMI GmbH is widely recognised as a market problems arise it is usually the case that the mould is not leader in the production of explosion-proof solvent debinding optimally designed for the processing of feedstocks. Hartmut furnaces for PIM. As water debinding becomes more Walcher and Marko Maetzig, from Arburg GmbH + Co KG, important for PIM producers, the company reports on the discuss the specific requirements that a PIM mould must latest innovations in its range of debinding systems for the satisfy and outline measures that can enable component industry. quality to be significantly increased. 47 Maxon Motor GmbH: A PIM manufacturer Technical papers driven by precision The Swiss tradition of manufacturing high precision 81 The development of an innovative continuous components and mechanisms is alive and well at the Maxon belt furnace for the high temperature sintering Motor plant in Sexau, Germany. Here Switzerland’s Maxon Motor group has a PIM operation for the production of metal of MIM and CIM products S K Robinson and ceramic components for both in-house use and external customers. Dr Georg Schlieper reports for PIM International on a recent visit. 86 New two-unit one step batch debinding and clean sintering system for improved efficiency 57 Arburg celebrates 50 years of PIM expertise and carbon control in the MIM process with a major international conference G Matula, I Mohsin Arburg GmbH + Co KG recently celebrated 50 years of involvement with PIM by organising a major international 91 MIM industry expansion: What does it mean for conference for customers and partners at its headquarters vacuum furnace technology? in Lossburg, Germany. We report on event highlights. J Balinnang, A Goldsteinas

67 Developments in PIM materials and processing at PowderMet 2013 Chicago Although the increasing popularity of MPIF’s spring MIM Regular features conference has, to some extent, diminished the coverage of the technology at its international all-subject summer 4 Industry news conference, there remained more than enough content at 80 Global PIM patents PowderMet 2013 to capture the attention of MIM devotees. Dr David Whittaker reports for PIM International. 96 Events guide, Advertisers’ index

Industry News CombiCombi FurnaceFurnace forfor CatalyticCatalytic oror ThermalThermal DebindingDebinding Combi Furnace for Catalytic or Thermal Debinding To submit news for inclusion in Powder Injection Moulding International please contact Nick Williams [email protected] andand SubsequentSubsequent PresinteringPresintering and Subsequent Presintering

Cinven, added, “We are delighted to Cinven invests in German CIM partner with Dr Zimmermann and specialist CeramTec his experienced team in CeramTec’s ChamberChamber retortretort furnacefurnace Chamber retort furnace transition to an independent company. forfor catalyticcatalytic debindingdebinding oror for catalytic debinding or We support the Company’s strategy European private equity firm Cinven “Our Fund investment in CeramTec of ongoing investment that includes forfor thermalthermal debindingdebinding andand for thermal debinding and announced in June that it has reached builds upon Cinven’s expertise across the plant expansion in Marktredwitz, subsequentsubsequent presinteringpresintering subsequent presintering an agreement to acquire CeramTec both the industrial and healthcare and new product initiatives such as from Rockwood Holdings, Inc. for a sectors, and our previous successful LED lighting and semiconductor LessLess sinteringsintering capacitycapacity Less sintering capacity total consideration of €1.49 billion. investments in Germany. Consistent applications.” CeramTec is a leading global with our investment focus, CeramTec Dr Ulf Zimmerman, CEO of neededneeded needed manufacturer of high performance enjoys leading competitive positions CeramTec, stated, “We are glad to ceramics, including those produced in markets with strong underlying be working with the Cinven team. EasyEasy transfertransfer toto thethe Easy transfer to the by Ceramic Injection Moulding (CIM), growth. We are particularly impressed They have an excellent track record sintersinter furnace,furnace, binder-binder- sinter furnace, binder- for application in medical, automotive, with CeramTec’s ability to consistently of supporting companies to grow freefree atmosphereatmosphere duringduring free atmosphere during industrial and electronic end-markets. launch high value, innovative products globally in both the healthcare and The company’s proprietary product through economic cycles. We are keen industrial sectors. Cinven’s investment sinteringsintering sintering portfolio includes hip joint prostheses to support the Company’s growth will enable us to capitalise on the components, including the Biolox outside its core European markets, opportunities in our existing markets TmaxTmax 600600 °C°C oror 900900 °C°C Tmax 600 °C or 900 °C brand, high speed cutting tools and specifically in North America and Asia, as well as further expand the business ballistic ceramics for armour. In 2012 both organically and through acquisi- internationally.” AtmosphereAtmosphere circulationcirculation Atmosphere circulation the company generated revenues of tions. Most recently, we have achieved Rockwood Holdings is disposing €425 million. Its main operations are strong growth in the US for our of CeramTec as part of a broader AdvancedAdvanced safetysafety systemsystem Advanced safety system located in Plochingen, Germany, and portfolio companies - examples include repositioning of the Group. Completion withwith fail-safefail-safe PLCPLC forfor safesafe with fail-safe PLC for safe CeramTec employs more than 3,000 Phadia, Sebia and CPA Global. In is expected during the third quarter of people across 18 facilities worldwide. Asia, we have the benefit of our highly 2013 subject to customary regulatory operationoperation withwith nitricnitric acidacid operation with nitric acid Bruno Schick, Partner and Co-Head experienced Asian portfolio team.” approvals. and/orand/or optionallyoptionally withwith and/or optionally with of Cinven’s German team, stated, Pontus Pettersson, Principal at www.ceramtec.com flammableflammable processprocess gasesgases flammable process gases NitricNitric acidacid pumppump Nitric acid pump ExhaustExhaust torchtorch NRANRA 40/06 40/06 CTDB CTDB Exhaust torch NRA 40/06 CTDB ® Feedstock for MMIMetal InFEEDSTOCK:jection Molding ADVAMET StandardStandard sizessizes 4040 andand 150150 ll Standard sizes 40 and 150 l

At Advanced Metalworking Practices feedstock pFeedstockroduction is o uproductionr only business . Customized feedstock At Advanced Metalworking Practices feedstock Our products are used widely for applications in fromindust r25ies stouc h1700 as me dlbica inl a nd made from numerous production is our only business. Our products are orthodontic, electronics, hardware and sporting goods. AA widewide rangerange ofof respectiverespective CIMCIM andand MIMMIM sinteringsintering furnacesfurnaces isis available,available, seesee catalogcatalog A wide range of respective CIM and MIM sintering furnaces is available, see catalog one batch ferrous and non-ferrous used widely for applications in industries such as ISO 9001:2008 certified Contacts: „Advanced„Advanced Materials“Materials“ onon thethe webweb „Advanced Materials“ on the web William R. Mossner Supplier of quality feedstock ADVAMET ® metals and alloys Off-the-shelf standard Dwight Webster medical and orthodontic, electronics, hardware Feedstock production from 25 lb to 1700 lb in one batch Advanced Metalworking Can supply customers with lower cost, off4605-the-she Alloylf, Steel and Practices, LLC and sporting goods. 401 Industrial Drive standard 4605 Alloy Steel and 17-4 PH Stainless 17-4 PH stainless Carmel, IN 46032, USA Supplier of Customized feedstock made from numerous e-mail: [email protected] ferrous and non-ferrous metals and alloys. Phone: +1 317 843 1499 Fax: +1 317 843 9359 Advanced Metalworking Practices, LLC High Quality Feedstocks since 1988 EuroPMEuroPM EuroPM 4511 West 99th Street Phone: +1 317 337 0441 - longer than any other supplier Carmel Fax: +1 317 337 0455 Gothenburg/SwedenGothenburg/Sweden Gothenburg/Sweden www.advancedmetalworking.com IN 46032 www.amp-llc.net SeptemberSeptember 15-18, 15-18, 2013 2013 September 15-18, 2013 USA [email protected] MadeMade Made ISO 9001:2008 Certified BoothBooth 87 87 Booth 87 inin in www.nabertherm.comwww.nabertherm.com GermanyGermany www.nabertherm.com Germany Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 5 4 Headquarters:Headquarters: Nabertherm Nabertherm GmbH GmbH . .28865 28865 Lilienthal/Bremen, Lilienthal/Bremen, Germany Germany . .Tel Tel +49 +49 (4298) (4298) 9220 9220 . .Fax Fax 129 129 . [email protected] [email protected] Headquarters: Nabertherm GmbH . 28865 Lilienthal/Bremen, Germany . Tel +49 (4298) 9220 . Fax 129 . [email protected]

® Indo-MIM announces record turnover Catamold and major expansion plans Imagination is the only limit!

Indo-US MIM Tec Pvt. Ltd, the world’s a turnover of Rs. 500 crores (approx. largest Metal Injection Moulding US$76 million) in the fiscal year 2013. producer based in Bangalore, Karna- Indo-MIM, which has offices in the taka State, India, reports that it is plan- USA, Europe, India and China, has ning an investment of Rs. 350 crores customers in more than 30 countries (approx. US$53 million) in the region worldwide across a wide number of over the next three to five years and industry segments. ® expects to reach sales in this period Dr Krishna Chivukula, Chairman 2013 MPIF award winning MIM automo- [ Catamold – Inject your ideas ] of Rs. 1200 crores (approx. US$180 of Indo-MIM, stated, “We are growing tive sensor components manufactured by million) while adding 1000 more year on year at an approximate rate of Indo-MIM (Courtesy MPIF) employees. The company registered 30% and expect to do a turnover of Rs. 1200 crores [approx. US$180 million] in three to five years. During 2014 fiscal year and ensuing five years, Indo-MIM plans to aggressively increase its capacity in Bangalore and in select countries overseas, thereby ensuring its pre-eminence in the MIM industry.” Established in 1998, Indo-MIM has since expanded its facilities into the largest installed MIM capacity in the world with around 2000 employees in Bangalore. In addition to MIM, the company also offers precision machining and surface treatments for the aerospace sector and has an investment casting facility in Tirupati, BASF SE Andhra Pradesh, specialising in the GBU Carbonyl Iron Powder production and export of investment and Metal Systems castings for the automotive sector. Powder Injection Molding Indo-MIM received three of the eight G-CA/MI – J513 Metal Powder Industry Federation 67056 Ludwigshafen, Germany (MPIF) PM Design Excellence Awards Phone: +49 621 60 52835 at the recent PowderMet Conference in E-mail: [email protected] Chicago, Illinois, USA. After receiving Internet: www.basf.de/catamold the awards Dr Shivashankar, Vice

President Operations, stated, “It feels great to be globally recognised for the products we manufacture using MIM. These recognitions always motivate us to convert and manufacture lot more complex products via MIM and bring much needed cost savings to our

customers”. Discover the amazing possibilities of metal and ceramic components Krishna Chivukula Jr., CEO, Indo- manufacturing using Power Injection Molding with Catamold® and BASF. MIM added, “Winning parts of Indo- MIM in the awards aptly demonstrate With Catamold®, conventional injection molding machines can be used to that the technology is not resting on its produce geometrically demanding components economically. You can do laurels, but these exemplary compo- injection molding of metal and ceramic feedstock as easily as plastic. nents fabricated via MIM signal a push And this opens up new means of producing complex components that into new territories. This recognition provide economic and technical beneﬁ ts in sectors ranging from Automotive, by our industry gives us an assurance Consumer Products, and Mechanical Engineering to Medical Products and that our valued customers are satisfied Communications/Electronics. with the technology we provide and at Take advantage of the new diversity in Powder Injection Molding with Catamold®. the same time we are carving a niche Get in touch with us – we’ll be glad to help you on the road to success. at every step to achieve our ultimate goals.” www.indo-mim.com ®= registered trademark of BASF SE

6 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 7

EPSON ATMIX CORPORATION Schunk Group celebrates its 100th Group’s Materials Division along with technical ceramics, pantograph contact Jubilee strips, etc. The Powder Metallurgy products The Schunk Group, with its head- world. This is also evident in the are produced at three main plants in quarters in Heuchelheim, Germany, extraordinarily strong loyalty our the Schunk Sinter Metals Division, celebrated its 100th Jubilee in August employees have to the company.” two of which are located in Thale and with its approximately 8,300 employees Schunk sees its large investments in Giessen, Germany and another in at more than 60 locations worldwide its facilities, which the company makes Mexico. Thale specialises in larger PM joining in the celebrations. all over the world, as also being an parts produced on powder presses The company was founded by investment in and for the employees. ranging from 150 to 1500 metric Ludwig Schunk and Karl Ebe as “With a great deal of commitment tonnes force and also Metal Injection Schunk & Ebe in Fulda in 1913 for and creativity, our employees have Moulded parts, whilst the PM plant in the production of carbon brushes for continually developed Schunk into Giessen produces smaller PM parts, dynamos and engines. After Karl Ebe what it is today, a successful globally PM bearings and sintered filters with passed away, Ludwig Schunk led the operating technology corporation. The powder press capacity up to 150 tons. company successfully until his death in many exciting jubilee events being held The Schunk Sinter Metals Division 1947. In his will Ludwig Schunk stipu- this year at all our facilities are first contributed around €140 million to lated that the company be preserved and foremost a way of thanking all our Group sales of €930 million in 2012. as a Foundation for the employees, staff,” says Federer. The Schunk Group recently reported Finer Powder Production and the Ludwig-Schunk-Stiftung e.V. In the hundred years since its estab- that Gerhard Federer, CEO of the Foundation was established. lishment, Schunk & Ebe has become Schunk Group, will retire from his “Ludwig Schunk’s will still shapes a globally operating corporate group position with effect from October 31, Cleaner Powder Production our corporate culture,” stated CEO with four divisions; Schunk Materials, 2013 due to health reasons. He will be Gerhard Federer. “It obliges us to Schunk Sinter Metals, Weiss Group succeeded on November 1, 2013 by Dr continually develop and maintain the (environmental simulation and climate Arno Roth, a long-time member of the Shape Control of Powders company’s independence. Our business technology) and Schunk Sonosystems Management Board who is currently strategy geared towards long-term (ultrasonic joining technology). The responsible for the Weiss Group and growth makes Schunk a secure and original product range covering carbon Sonosystems divisions. attractive employer throughout the brushes are today produced in the www.schunk-group.com • Low Alloy Steel

High Purity Spherical Nickel Powders • High Alloy Steel tailored for MIM • Stainless Steel • Magnetic Materials Tapped Type 4SP nickel powder is a high purity, spherical nickel d10 d50 d90 Density powder that is ideal for making powder metal parts SNP-400 4.4 11.4 25.2 5.57 • Granulated Powder where high sintered density and controlled shrinkage are 4SP-10 3.0 6.3 11.2 5.48 important. SNP-20+ 10 7.2 11.4 17.1 5.45 SNP+20 12.6 20.8 34.6 5.37

With excellent consistency, narrow PSD and spherical morphology, Type 4SP-10 nickel powder is the ideal choice JAPAN for the metal injection molding (MIM) industry. Mr. Numasawa, Ryo [email protected] U.S.A and SOUTH AMERICA Novamet Specialty Products Corp. Mr. Pelletiers, Tom 681 Lawlins Road, Suite 10 ASIA and OCEANIA [email protected] Wyckoff, NJ 07481, USA TEL: +1 201 891 7976 FAX: +1 201 891 9467 Mr. Yoshida, Shunsuke EMAIL: [email protected] [email protected] EU www.novametcorp.com Dr. Pyrasch, Dieter CHINA [email protected] Mr. Ota, Arata [email protected] KOREA Mr. Yun, John 8 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 9 [email protected] Industry News | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email | Industry News PIM Binder Systems

Call for Presentations issued Programme from Emery Oleochemicals for MIM 2014 Conference, Long published for 32nd Beach, USA Hagen Symposium

The program committee for MIM2014, The program committee requests The Fachverband Pulvermetallurgie the International Conference on that abstracts be submitted by (FPM) has published the technical Injection Molding of Metals, Ceramics September 30, 2013, for consideration. programme for the 32nd Hagen Sympo- and Carbides, has issued a Call Complete details on the conference sium scheduled to take place in Hagen, for Presentations. The focus of the and on submitting abstracts are avail- Germany, November 28-29 2013. technical program is Materials and able from the Metal Injection Molding The programme will include presen- APPLICATION Component Integrity. Association’s website www.mimaweb. tations on modern methods for quality Sponsored by the Metal Injection org or by contacting Jim Adams at control in mass production processes For compounding both ceramic and Molding Association, a trade associa- [email protected] such as Powder Metallurgy, including tion of the Metal Powder Industries ferrous PM, hardmetals, ceramic and carbide powder blends Federation, and its affiliate APMI Metal Injection Moulding, plus methods International, the conference will for corrosion testing, surface analysis, be held in Long Beach, California, and process modelling. February 24–26, 2014, at the Hyatt The symposium will include the FEATURES Regency Long Beach. presentation of the Skaupy Prize 2013 Technical program Co-Chairmen to Josef Seyrkammer of Miba Sinter • Approved for feedstock systems Bruce Dionne, Vice President/General Austria GmbH in Vorchdorf, Austria. Manager, Megamet Solid Metals, Inc., Seyrkammer will present a keynote based on Al-oxide, Zr-oxide, Si-nitride, and Uwe Haupt, Key Account Manager, paper entitled “Road to Success Si-carbide and W-carbide Arburg GmbH + Co KG, request for Powder Metallurgy” in which he abstracts of 100–150 words, covering will review some of the technology any aspect of metal injection moulding, highlights during a career of almost 50 • Top quality feedstocks for both powder including processing, materials, and The Hyatt Regency Long Beach, venue for years with Miba Sinter. injection moulding (PIM) and powder applications. www.pulvermetallurgie.com the MIM 2014 conference extrusion moulding (PEM) machines as well as film and foam sheet applications

• High strength of green and brown moulded parts

• Sintered densities of more than 97.5 %

• Binder for compression moulding applications

16.-23. October 2013 Düsseldorf, Germany We are again exhibiting at this years K-Show and we are looking forward to welcoming you to our stand (Hall 8b / A 62) when we discuss the PIM application with you.

Emery Oleochemicals GmbH Henkelstr. 67, Building L10, 40589 Düsseldorf T | +49 211 5611 2000 F | +49 211 5611 2600 E | [email protected]

10 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 CREATINGVol. 7 No. 3 ©VALUE 2013 Inovar Communications | www.emeryoleo.com Ltd September 2013 Powder Injection Moulding International 11

New MIM design “app” available for 2014 PM World Apple devices Congress set for

An new app to assist engineers with powerful tools Orlando, USA the design of their complex metal of this app is The 2014 World Congress on components for the Metal Injection the ability to Powder Metallurgy & Particulate Moulding (MIM) process has just been find a material Materials – PM2014 will take place released. The app has been developed solution at the Walt Disney World Dolphin by US MIM producer Kinetics Climax based on Hotel, Orlando, Florida, USA from VISIT US AT: Inc., based in Wilsonville, Oregon. the property May 18–22 2014. “Kinetics MIM” is a new smart criteria of your Organised and sponsored by the Euro PM2013: booth 48 phone application specifically application. Metal Powder Industries Federation developed for design engineers who From the list (MPIF) in cooperation with APMI are interested in getting metal alloy of material International, PM2014 will be the selection and design advice for their solutions most important international PM potential Metal Injection Moulding you have the event of the year. components. The Material Selector option to add Along with an all topic technical matches material performance criteria to your favour- programme a number of special to suitable alloys and then provides ites or email subject areas have been identified material property data sheets. The the material for special interest programs, these accompanying design guide helps data sheet. Our industry leading include: designers get the most from MIM by Design Guide is now at your fingertips, defining MIM design requirements the paper bound guide that you are • NDT/Failure Analysis across a wide range of searchable accustomed to picking up at industry • Machinability categories, and includes illustrative tradeshows can now be utilised on your • Fatigue figures. smartphone.” • Technologies for PM Growth. The first MIM app of its kind, The Kinetics MIM app is available A major trade exhibition will Kinetics states that it is designed by free of charge from the the Apple also feature international suppliers engineers for engineers and will help AppStore. of metal powders, components, end-users select the right material for www.kinetics.com equipment and related services. their application. “One of the unique www.mpif.org

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Olle Grinder and Roger Lawcock How do you recognised at PowderMet 2013

APMI International, the professional technology, and is one of the leading society for the PM industry, welcomed experts on the subject of Hot make PIM Dr Olle Grinder, Consultant, PM Isostatic Pressing (HIP). A recipient Technology AB, and Roger Lawcock, of a PhD in metallurgy and material Director, Product & Process science from the Royal Institute of Development, Stackpole International, Technology, Sweden, in 1977, he has to the 2013 Class of Fellows. They made significant contributions in the parts stronger? Dr Olle Grinder (left) and Roger Lawcock received the award at a special PM sintering of high alloys, including tool (right) receive the 2013 APMI Fellow Industry Recognition Luncheon held steels, stainless steels, and cemented Award during PowderMet2013, June 24-27, carbides. He is author/co-author of Chicago, USA. four patents, two of which directly as the SAE Arch T Colwell Award for Dr Grinder is a world renowned related to PM, and has been a lecturer significant contribution to literature. With post-sinter hot isostatic pressing, not only do powder metallurgist who has actively at the Royal Institute of Technology for Lawcock received the MPIF Distin- you get stronger PIM parts, but now the process contributed to the advancement of over 25 years. guished Service to Powder Metallurgy PM technology in Europe, Asia and Lawcock is one of the pioneers award in 2013. He received his MSc is more efficient and cost effective than ever with North America. He is a member of the of the roll-densification process for in metallurgy from the University of International Liaison Committee of gears, converting numerous gears Manchester, UK, in 1987. During over Uniform Rapid Cooling from Avure Technologies. the International Journal of Powder from wrought to PM. A member of 30 years in PM, Lawcock has focused Metallurgy and has written articles for APMI for nearly 20 years, Lawcock on high volume, high performance Maximum density for superior strength and durability the Journal’s Consultants’ Corner. A has promoted the advancement of automotive applications based on lean ü member of APMI for over 27 years and PM as a science by disseminating alloys, high temperature sintering and ü Zero internal porosity means less machining and better possessing over 43 years of PM experi- and exchanging information through improvements to core and surface surface finish ence, Grinder has published 60 reports his many publication efforts. He density. Lawcock has been instru- Exclusive Uniform Rapid Cooling for fast, economical in international journals or conference received the MPIF Howard I Sanderow mental during the material and design ü High-capacity units for up to 500 lbs. per proceedings. Outstanding Technical Paper Award development phases of several award batch processing cycle (if required, larger models can process Dr Grinder has made unparalleled as the outstanding technical paper at winning components. thousands of pounds per cycle) contribution in fully dense PM the 2005 annual conference, as well www.mpif.org Uniform Rapid Cooling reduces cycle times by up to 70%, dramatically cutting the per-unit cost of HIPing PIM parts. Up to Jiangxi Yuean Superfine Metal Co., Ltd three cycles can be completed in a single 8-hour shift. Tel: +86 797 8772566 Fax: +86 797 8772255 www.yueanmetal.com ü Improved tensile strength ü Maximum hardness Powders for MIM ü Greater corrosion resistance ü Minimal grain growth and distortion. • Carbonyl iron powder Compact models for up to 55 lbs. per cycle • Gas atomized powder Download a FREE white paper now at • Water atomized powder www.avure.com/pim

The white paper describes current and future trends in hot isostatic pressing. You’ll also German Office European Distributor American Distributor receive a data sheet on uniform rapid cooling. YUELONG GmbH PMC tec United States Metal Powders Inc. Tel: +49 681 8390 9269 Tel: +49 3947 776European 320 Office Tel: +1 908 782 5454 HeadquartersFax: +49 681 9384 947 Fax: +49 3947 776 330 Fax: +1 908 782 3489 Email: [email protected]

14 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications LtdThe GlobalSeptember 2013 Leader Powder Injection in Isostatic Moulding International Processing15

JPMA elects new president

The Japan Powder Metallurgy Association (JPMA) announced at its General Assembly that Mr Tetsuo Ito of Hitachi Chemical Co Ltd will take over as President of Powder Metal Sintering - Brazing - Metal Injection Molding - Hard Metal Reduction - Activated Carbon - Calcining - Annealing the association from Mr Kazuyoshi Tsunoda. The JPMA also reported a number of changes to its board at the General Assembly held on May 23. Mr Tetsuo Ito is the new www.jpma.gr.jp President of the JPMA

University of Trento Rotary drum Furnace Multitube-Pusher Furnace

Since 1933 ELINO INDUSTRIE-OFENBAU GMBH has been delivering custom-specific heat treatment equipment. Elino has delivered more than 4,000 furnaces worldwide, successfully hosts EPMA’s tailor-made high-tech systems providing renown German quality & reliability. 2013 PM Summer School

Elino’s wide product range consist of batch & continuous (gas fired or electrically heated) furnaces completly “Made in Germany“ The University of Trento hosted the latest EPMA Powder Metallurgy Summer School, which took place 8 - 12 July • with temperatures up to 2.600°C 2013 in Trento, Italy. The annual summer school, organised • with atmospheres being toxic, aggressive, vacuum, high pressure, flammable, reducing and neutral by the European Powder Metallurgy Association, provided 52 • with product sizes from nanometers to tons students from a variety of academic and industrial backgrounds with an introduction to PM by a number of highly Elino’s very well equipped testing laboratory allows for material experimentation and process validation of in middle-scale furnaces to define relevant application parameters. regarded academics and lecturers from industry. Together with customers a huge number of new methods of production as well as new products were developed in the laboratory and successfully brought into the market. Professor José Torralba from the Universidad Carlos III de Madrid, coordinated the event in conjunction with Professor Alberto Molinari and his team from the University of Trento. Continues MIM pusher Furnace Lectures were complemented by the University of Trento’s (Made in Germany) laboratory facilities and as part of the practical side of the • Elino manufactures continues MIM furnaces (approved technology) having low carbon level and complete debinding in event the students visited two companies; Mimest, who stainless steel without water injection system. produce typical MIM parts, and Eurocoating, a medium sized • Elino continues MIM furnaces also consume 3-4 times less process gas and cost effect worldwide. company working in biomaterials. Participants also received • Best ever corrosion resistance in stainless steel parts is achieved by Elino pusher MIM furnace worldwide. complementary copies of both PIM International and Powder Continues MIM Pusher Furnace Metallurgy Review. Joan Hallward, Summer School Coordinator stated, “This year’s Summer School programme has benefited from the ECO-MIM one step debinding batch furnace University of Trento’s superb laboratory facilities and well (Made in Germany) located hotels. No Summer School would be complete • One-step complete debinding unit including pre-sintering up to 900°C without the now traditional Summer School dinner and song • Convection system i.e. temperature homogeneity better than ±5 °C contest held on the last evening of the course at a local • Special off gas burner unit (environment friendly) restaurant, where everyone sang to their heart’s content.” • Changeable process gases e.g. H , N , N -H , Ar, Air etc. 2 2 2 2 www.epma.com ECO-MIM one step debinding + pre-sintering

ECO sintering batch furnace (PM/CIM/MIM (Made in Germany) • up to 1450 °C with temperature accuracy of ±3 °C • Clean sintering i.e. energy/cost saving

• Process gases N2, H2, Ar, N2-H2 partial pressure or slight over pressure and vacuum • Vacuum up to 10-5 with Tubular pump ECO-MIM sintering

ELINO INDUSTRIE-OFENBAU GMBH Tel: -+49 (0)2421 - 69020 Fax: +49 (0)2421 - 62979 Zum Mühlengraben 16-18 [email protected] Participants at the EPMA 2013 PM Summer School 52355 Düren - Germany www.elino.de

16 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 17

Debind & Sinter

support more than 100 new program GKN plans new regional headquarters launches in the next three years for for the Americas GKN Driveline and GKN Sinter Metals,” Willig said. “Our new headquarters GKN Driveline and GKN Sinter Metals GKN Sinter Metals is the world’s facility underlines our commitment to are expanding their automotive opera- largest producer of precision powder our customers and to the Americas.” tions and moving to a new regional metal products, including a major MIM “The increase in demand for our headquarters for the Americas in the production facility in Germany. technology-leading driveline systems Detroit suburb of Auburn Hills early GKN’s new headquarters complex made it essential for us to find a suit- next year. will provide additional space for able facility to support projected growth The new site will also house state-of-the-art testing and valida- and better serve our customers.” employees from GKN’s Land Systems tion equipment along with additional Chris Franks, President, GKN and North American Services groups. engineering design areas for driveline Sinter Metals Americas, added, “The Construction of the 168,000 ft2 facility and sinter metal products. Executive additional space is ideally located in ® was scheduled to begin in August on an management teams from both GKN close proximity to many of our global TITAN DS delivers the best in…debinding and sintering. 11.2 acre site at 2150 N. Opdyke Road, Driveline and GKN Sinter Metals will customers and will give us access to the location of a now-vacant Showcase be located in the new headquarters the additional resources needed to Cinema complex. building along with various engineering provide our customers with world-class Headquartered in Auburn Hills groups and other corporate activities. precision powder-metal products and since 1986, GKN has more than 300 Robert Willig, President of GKN allow us to deliver on our corporate employees at its current 113,000 ft2 Driveline Americas, noted that the need vision of providing “Engineering That Backed by 65 years of thermal processing expertise, Ipsen’s new sintering and facility at 3300 University Drive. for additional space and resources has Moves The World.” debinding furnace, TITAN® DS, upholds our reputation for quality. Ipsen delivers the Employment is expected to grow by become paramount in view of GKN’s GKN officials also acknowledged 50 or more full-time employees in the substantial growth in recent years and “the tremendous support” provided for best through better performance and better features for less cost, bringing the MIM next three years. the number of major new program the project by Michigan Governor Rick and Powder Metallurgy industry one step forward. GKN Driveline is the world’s leading launches planned for the Americas. Snyder’s office, the Michigan Economic producer of automotive driveline “GKN has significantly increased Development Corporation and the City Benefits components and systems including its engineering resources in the past of Auburn Hills. constant-velocity-joint, all-wheel-drive, four years and plans to recruit and hire www.gkn.com • Reduced door-to-door cycle time trans-axle and electric-drive systems. even more engineering personnel to AT&M 2013.pdf 1 31/01/2013 15:12 • Unbeatable price-to-volume ratio for specialized MIM furnaces • Precise process control for consistent part quality • Short delivery time with rapid start-up • One global standard • Modular design for ease of production flow optimization STOCK CODE:000969

Technical Information NEW PLANT TO PROVIDE AT&M WITH A TOTAL CAPACITY OF 4000 TONS OF • Work zone size: 915 mm x 915 mm x 1,220 mm (36” x 36” x 48”)

C ULTRA-FINE POWDER FROM EARLY • Hearth gross load weight capacity: 2,700 kg (6,000 lbs)

M SPRINGTIME 2013 • Maximum operating temperature: 1,400°C (2,550°F) Ultra-fine powders series: stainless steel, superalloy Y low alloy steel, high-speed steel, soft magenetic alloy • Temperature uniformity: better than +/- 5°C (+/- 10°F) CM • Ultimate vacuum level: < 7 Pa (50 microns) MY

CY • Nitrogen, hydrogen and argon partial pressure for operation up to

CMY 13 mbar (10 Torr) K • Internal nitrogen or argon gas cooling up to 2 bar

Water atomised 17-4PH (AT&M standard) Watter atomised 17-4PH (shape optimized) • 3 heat trim zones AT&M at least wish to give a simple hint to typical particle size like d50≈10 µm.

AT&M Co., Ltd Powdered Metal Division Sales Agent in Europe No. 76 Xueyuannanlu Haidian Tel: +49(0)211.30 13 91 35 Visit www.IpsenUSA.com/TITANDS Beijing,100081, China E-mail: [email protected] to learn more about TITAN DS. Tel:+86(10)-62443881 Email:[email protected] http://www.atmcn.com

www.IpsenUSA.com/TITANDS

Dr Seung Eon Kim, Korea Institute Stage set in New Zealand for major of Materials Science (KMS) titanium PM conference • Dr Hilda Kundai Chikwanda, CSIR, Materials, Science & Manufac- Organisers of the International • Titanium Technologies in Powder turing, South Africa (Topic TBC). Titanium Powder Processing, for Manufacturing Many Australian and New Zealand Consolidation and Metallurgy John Barnes, CSIRO, Australia guest speakers are also presenting, conference in Hamilton, New Zealand, • Low-Cost Processing of Titanium including speakers from the Callaghan Leading the Way in the December 2-4 2013, have announced and its Alloys Institute, universities across New a number of key international guest Dr Ashraf Imam, Naval Research Zealand and Australia and leading Production of Plasma speakers to be included in this year’s Laboratory, USA titanium manufacturers. technical programme. • Metal Injection Moulding of beta- The invited speakers come from Atomized Spherical titanium alloys The Titanium Industry Development over ten countries and are leaders Dr Thomas Ebel, Geesthacht Association in the field of titanium Powder Metal Powders Centre for Materials and Coastal New Zealand’s Titanium Industry Metallurgy. “The calibre of speakers Research, Germany Development Association (TiDA) confirmed from both research and was estbalished in 2010 to develop • Porous titanium structures: their Products industry arenas is shaping the and promote the country’s titanium fabrication and applications TiDA’s new Laser Sintering machine is able to produce intricate conference to be a not to miss event PM industry. The association is Titanium Grade 1 Professor Huiping Tang, State parts in titanium, stainless steel and many other metals ◦ for powder specialists,” stated Dr achieving this through research and Titanium Alloys Ti-6Al-4V 5 & 23 Ma Qian, Science Director, RMIT Key Laboratory of Porous Metal ◦ development, education and training in titanium powder technology. The titanium applications Australia and Conference Committee Materials, China Nickel-Titanium and the provision of a platform for industry could be worth $700 million each year to New ◦ member. The list of international • Processing of dense and porous companies to start to use the various Zealand by 2020. The opening of this centre is an excellent ◦ Niobium guest speakers and topics currently titanium parts by powder injection titanium powder technologies available. example of the innovative ecosystem at work. The industry, And Other High Melting Point Metals includes: moulding of titanium hydride ◦ Dr Wayne Mapp, New Zealand’s the Bay of Plenty Polytechnic and the University of Waikato Professor Efrain Carreno-Mortelli, • Development of Large Sized Ti Minister of Science and Innovation, have pooled their resources to make this happen. It is HES-SO Institute of Systems Alloy Compacts for Aerospace stated at the opening of the facility, exactly the sort of innovative project that will drive our Engineering, Switzerland Application by Advanced Powder “TiDA is a key piece of infrastructure economic growth.” Processing – MIM • Layer manufacturing of porous for the titanium industry. It will TiDA has today built a world-class advanced powder Professor Hideshi Miura, Kyushu titanium for biomedical applica- significantly boost New Zealand’s metallurgy research centre featuring state-of-the-art University , Japan tions advantage in the industry, especially testing and prototyping equipment. The facility also provides specialist metallurgy training to provide skills and knowledge for the emerging titanium powder metallurgy and metals testing industries. New Zealand currently has a research programme covering a range of Ti powder areas. The research group includes two universities, two government research organisations and TiDA. Commenting on the potential for titanium PIM CM Furnaces, long recognized as an industrial leader in performance-proven, high technology in New Zealand, TiDA told PIM International, temperature fully continuous sintering furnaces for MIM, CIM and traditional press “We believe there is a good opportunity for titanium PIM in and sinter now OFFERS YOU A CHOICE, for maximum productivity and New Zealand as the technology reduces processing costs. elimination of costly down time. This makes the use of titanium available to a broader range of applications. Companies designing products can look at Choose one of our exclusive BATCH hydrogen atmosphere Rapid Temp furnaces. the design based on what they want it to achieve and utilise Designed for both debinding and sintering, these new furnaces assure economical, the superior benefits of titanium alloys. The end result can often be a product which is cheaper than using a material simple and efficient operation. that has a lower cost per kg, which is manufactured OR... choose our continuous high temperature sintering furnaces with complete competitively and which displays the ideal properties of titanium alloys including high corrosion resistance, automation and low hydrogen consumption. biocompatibility, excellent weight to strength ratio etc.” TiDA has recently installed a Laser Sintering (3D CONTACT US for more information on our full line of furnaces with your printing) machine that is able to produce intricate parts choice of size, automation, atmosphere capabilities and in titanium, stainless steel and many other metals. This temperature ranges up to 3100˚F / 1700˚C. machine is one of only a few commercial machines of its kind operating in Australasia and it has manufactured items that are widely varied from body implants and complex machinery parts, to high spec sporting equipment and jewellery. Added to this, a newly acquired vacuum E-Mail: sintering furnace which can reach up to 1600°C is used www.raymor.com [email protected] FURNACES INC. in the Metal Injection Moulding process. This machine is Web Site: 103 Dewey Street Bloomfield, NJ 07003-4237 the only one of its kind in New Zealand and available for Tel: +1 450.434.1004 http://www.cmfurnaces.com Tel: 973-338-6500 Fax: 973-338-1625 research or commercial purposes. www.tida.co.nz

job in re-organising the company, to Slovakian MIM producer Dion Vaughan appointed Chief hand over to Dion Vaughan to deliver an Gevorkyan to expand Executive of specialist metal powder exciting future for Metalysis.” Dion Vaughan, Chief Executive of production producer Metalysis Metalysis added, “Our future emphasis will be on further developing our Gevorkyan s. r. o., a MIM and PM parts producer based in Metalysis, the UK based specialist Tony Pedder, Chairman of Metalysis strength in science and technology, the Vlkanová area of Slovakia, has announced that it is to metals producer, has announced the commented, “The company has where the company has historically expand production and create 44 new jobs. appointment of Dr Dion Vaughan as performed well on its science and performed, and on partnering with The implementation of the €7.57 million investment Chief Executive. He succeeds Guppy technology goals, which has enabled leading metals companies who can will be spread over the period 2013 to 2016. The company Dhariwal who is retiring, having joined the Board and shareholders to develop help with engineering scale-up announced that it will receive investment aid of €1,510,000 the firm in 2010. Vaughan is a trained a new scale-up plan for the business. and market adoption. The company in the form of tax relief on income. The increase in metallurgist and has worked across This plan, based on simpler and is already making good progress production will be achieved through the extension of the the metals, mining and investment cheaper production cells, is a longer in exploring such partnering company’s existing manufacturing plant. Gevorkyan s. sectors including Hatch Corporate term plan and so it is a natural time arrangements.” r. o. was established in 1996 to manufacture PM parts Finance, Sheffield Forge Masters and for Guppy, who has done a very good www.metalysis.com for a wide variety of industries including automotive, JP Morgan. oil, cosmetics, hand tools, locks and security systems, Metalysis has developed an entirely medical devices and air conditioning. new way of producing high value metal The company’s expansion into MIM processing powders that, states the company, was announced in the September 2012 issue of PIM reduces the cost and environmental International. The company currently employs more than impact of metal production as 100 people. compared with existing processes. www.gevorkyan.sk The Metalysis technology is able to transform metal oxides, such as ores directly into metal powders in a single step. It is currently focusing on the high value specialist metals titanium Liquidmetal Technologies and tantalum. As a result Metalysis believes signs Manufacturers’ that it can play a critical role in two manufacturing revolutions over the See us on stand 64 Representation Euro PM2013 coming years. The powders produced PHOENIX Agreement with TM&S by the Metalysis process, states the company, will dramatically change PH PHOENIX Liquidmetal Technologies, Inc. (LTI), a leading developer of the production of high value titanium SCIENTIFIC amorphous alloys and composites, has signed a Manufac- components both utilising existing turers’ Representation Agreement with TM&S, LLC, also manufacturing techniques and driving INDUSTRIES SCIENTIFIC known as Technical Marketing and Sales. TM&S special- forward the adoption of 3D print in ises in the sales of Powder Metal and Metal Injection specialist metal products. Concept design to Moulded parts. “TM&S is a trusted advisor for established In addition, this new technology INDUSTRIES has the potential to significantly engineering reality customers that procure Powder Metal and MIM parts, who often find Liquidmetal provides significant performance or reduce the cost of specialty metal cost advantages,” stated Bruce Bromage, EVP of Business powder production. This means Europe’s specialist engineers Development and Operations at Liquidmetal Technologies previously expensive metals such as for design and manufacture of Derek Rasmussen, President of TM&S, stated, “Liquid- titanium can be used in a variety of innovative materials processing metal technology fills a critical gap for design engineers new applications to satisfy the latent systems and sourcing professionals that need high precision demand for a low cost, light weight, PM Tooling System parts in volume, and especially for those applications high strength and corrosion resistant  Atomisers that require high quality surface finish or strength. I am metal. The EROWA PM tooling system is the standard Hot/Cold Gas pleased to be able to offer this exciting technology to my The nature of the Metalysis process Water customers.” means that it can produce alloys interface of the press tools between the Vacuum Apex Business Park From their offices located in Minneapolis, Minnesota, that would not be cost effective by Gas Recycling Hailsham BN27 3JU, UK USA, TM&S works directly with design engineers and traditional processes. It is entirely toolshop and the powder press machine.  Powder Classifiers Tel: +44 (0)1323 449001 purchasing agents across the globe. solid-state; therefore metals with  Trial Powder Service Fax: +44 (0)1323 449002 www.technicalmarketingandsales.com significantly different densities or Its unrivalled resetting time also enables  Melt Spinners [email protected] melting points can be alloyed. These you to produce small series at a profit.  Wire Casters www.psiltd.co.uk innovative alloys can be tailored T to have the desired properties for applications within a variety of www.erowa.com Submitting News industries including automotive, To submit news to Powder Injection Moulding International marine, electronics, clean energy and aerospace. contact Nick Williams: [email protected]

ation. Importantly, this maximises to verify that the sample meets the Nanostructured consistency, dependable end-product expected high-standard at each stage performance and user-assurance. of processing, and properties such ceramic powder At the new facility, Innovnano’s as oxide content, phase and chemical developments at unique Emulsion Detonation Synthesis purity, particle size, and mechanical (EDS) technology has been fully performance, along with many others, Innovnano automated, and along with stringent are measured. quality control processes, ensures the André de Albuquerque, CEO of Innovnano, a manufacturer of high production of nanostructured powders Innovnano, commented, “Building this performance ceramic powders, has with extremely high batch-to-batch new manufacturing facility was a vital invested in a high-tech, brand new consistency. This ensures the ceramic move for us, and now guarantees that facility for production of its nano- powders are developed to exacting we can provide long-term support to structured powders, including 3 and 4 specifications with defined properties, all our customers, regardless of the mol % yttria stabilised zirconia (YSZ). for consistent chemical reliability and quantities of nanostructured ceramic The new site is based in a dedicated robust physical performance; charac- powders they require. Our patented technology park in Coimbra, Portugal, teristics which are then translated to EDS process lends itself perfectly to and has been designed to allow high the end-application, for example more industrial-scale production and there capacity expansion and industrial-scale efficient thermal barrier coatings or is no compromise to the quality or nanotechnology, enabling the produc- orthopaedic implants with enhanced performance of the final product.” tion of up to 1000 tonnes per annum. fracture toughness. Compared with Working to lead innovation in With the new facility, Innovnano has conventional microstructured ceramics, nanostructured ceramic powders, the capacity and expertise to rapidly powders with an intrinsic nanostructure Innovnano has established a close up-scale nanostructured powder translate to finer, denser and often a network of academic, R&D and production, from small quantities more chemically homogenous ceramic commercial institutes globally. This needed in R&D phases, to much larger material, enabling enhanced end allows Innovnano to gain first-hand industrial quantities, as and when properties such as hardness. insight into the capabilities and commercial progression dictates. As QA protocols include comprehensive constraints of existing materials, in such the company can provide support QC processes for each batch of powder turn enabling Innovnano to challenge and supply throughout a project at several steps throughout the produc- these limitations and develop powders life-cycle, negating the need to source tion process, from the raw material that are more optimally suited for alternative suppliers and eliminating to the final product. Industry tests purpose. any associated risk of product vari- are conducted with tight parameters, www.innovnano-materials.com

Powders MIM you can trust. HIP PTA Braze Laser Cladding Additive Manufacturing Thermal Spray PM Millforms

www.cartech.com

phone manufacturers in China. Clients Chinese MIM producer include as Foxconn, Oppo and Ginonee. Powder Metallurgy The total turnover of Shindy in 2012 Shindy creates graduate amounted to RMB 38 million and for Review: Autumn training partnership with 2013 it is projected at RMB 80 million. 2013 issue out now At the end of 2012 Shindy moved Central South University its production facilities to Guland, The latest issue of Powder Metallurgy Shenzhen, Guangdong Province, with Review, the magazine for the Powder Chinese MIM producer Shenzhen Shindy Technology Co., an area approximately 6500 m2. The Metallurgy industry, has just been Ltd and the Powder Metallurgy Research Institute of company has around 200 staff, with published and is available to download Central South University have entered into a joint venture 20 engineers engaged in R&D for new free of charge from www.ipmd.net. to establish an “Innovative Engineering and Education products. In order to meet its clients’ The 80 page issue features a Foundation” for the further training of graduate students ever increasing demand on quality, specially commissioned report on the from the institute employed full time by Shindy. Shindy told PIM International that it evolving relationship between North As part of the venture the institute’s senior teaching has made new capital investments in America’s PM parts producers and the Prof. Lin Yong of the Institute presenting and research staff will work on site at Shindy with its the latest models of injection machines region’s automotive industry, which has the joint venture plaque to Mr. Lin Sheng, management to organise a programme on marketing, from Arburg, Germany, as well as dominated the development of the PM General Manager of Shindy research and development, and production for trainees on sintering furnaces from Shimadzu, industry for many decades. the application and practice of their skills and knowledge in of encouragement from the local Japan. The company states that it is Also included is a review covering a practical setting. government to institutes to work committed to expanding its capabilities global R&D trends in hardmetals and On 27 June 2013 the inauguration ceremony took with industry to commercialise their in order to supply the medical, the phenomena of cobalt capping, place at the Grand Sky Hotel, Shenzhen. The Director technological developments, as well as automobile and consumer industries. as presented at the recent Plansee of the Economic Development Bureau of the Shenzhen creating job opportunities. The development of CIM technology is Seminar. An additional report covers Government, Mr. Zhu Yun, delivered a speech on the Shenzhen Shindy Technology Co., also reported to be underway. the Special Interest Program at the occasion. He stated that this joint venture will be a Ltd was established in July 2009 in For more information contact Sam PowderMet 2013 Conference, Chicago win-win situation for both parties and commented Shenzhen, Guangdong Province. Mok, Business Development Director, that looked at technologies for PM that it demonstrated a landmark success as a result The company is a manufacturer email: [email protected] growth. To download your free digital specialising in the production of MIM www.china-shindy.com edition of Powder Metallurgy Review, parts for the telecommunication visit www.ipmd.net/pmreview industries, in particular the mobile

Laboratory/ See us on stand 84 Production Z Blade Euro PM2013 .CO.UK Mixers

New MZ Sigma Mixer

Representatives of Shindy and the Powder Metallurgy Research Institute of Central South University at the ceremony

Mixing for Metal Injection Moulding? • Winkworth Laboratory/Production Z (Sigma) blade mixers - proven in Metal Injection Moulding • Used by Researchers and in Production - worldwide • Complete process control and monitoring • Easy Clean – just 5 minutes – batch to batch • Designed and Made in England A selection of MIM parts manufactured by Shenzhen Shindy Technology Co., Ltd For more information about Winkworth Sigma Z Mixers Call Sales on: +44 (0)118 988 3551 Submitting News E: [email protected] To submit news to Powder Injection Moulding International W: www.mixer.co.uk contact Nick Williams: [email protected]

T & D Molybdenum & Tungsten Manufacturing LLC Elino celebrates its 80th JPMA reports on 2012 Japanese anniversary and inaugurates MIM market Mo, W and Ta products a modernised technical ISO certified The Japan Powder Metallurgy Association (JPMA) has laboratory released its latest detailed annual report on the state of Japan’s MIM market. The report, which is based on figures • Mo, W, ML plates, sheets annealed for Elino Industrie-Ofenbau GmbH, the industrial furnace for 2012, shows that Japan’s MIM parts produced achieved shielding, 24” width manufacturer situated in Düren, Germany, recently total sales of 11.2 billion Yen, a 3.4% decrease on the previous celebrated its 80th anniversary. The opening of a modern- year. The association is forecasting that the 2013 results will • Mo, W, Ta, Ta-W heating elements made according to customer drawings ised R&D centre, where customised tests and research also reflect a level of stagnation in Japan’s MIM markets. can be carried out, was undertaken by the town’s mayor, The survey’s findings are based on the results of a detailed • Spare parts including sheets, ribbon, rods, Paul Larue. In his speech Larue praised the stability of questionnaire that was sent to 23 companies, including JPMA screw, hex nuts; boats, pins, wires and rivets. the company and underlined the fact that Elino plays an member and non-member companies. • Custom made Mo, W, TZM, ML, Ta pieces important role in the area’s industry. Elino, stated, Larue, In terms of application areas for MIM in Japan, the • Boats, trays, charge carriers, thermocouple has additionally always been exemplary with regards to the strongest growth was seen in the automotive sector, where protection tubes, all to customer drawings training and further education of young people in the town. sales grew to 20.1% of the market, up from 14.9% in the Elino is today a global supplier of industrial furnaces, • W and Mo crucibles previous year (Fig. 1). Industrial machine parts accounted PolyMIM GmbH is the first manufacturer offering including continuous and batch systems for Metal Injection for 20.4% of sales, up from 19.9% in 2012. Medical appliance • Annealing and sintering boats for PM and two different feedstock systems for metal Moulding. The company stated that it values a reputation MIM parts also saw a growth in market share to 17.4% compared injection molding: that has been built over 80 years for durable, service- to 14.6% in the previous year. IT parts sales dropped to 9.9% • W, Mo, TZM and Ta hot zones oriented furnace plants that today also have a strong from 17.5% in 2012 because, it is stated, because of order Customers have the choice between the • Mo, ML or TZM additional focus on energy efficiency. cancellations. standard and special feedstock grades of The company celebrated its anniversary together with In terms of materials usage, stainless steels rose to polyMIM - water-soluble binder system- ranging many long-standing customers and partners. Philippe T & D Molybdenum and Tungsten Manufacturing LLC account for 63.4% of sales, up 3% on 2012 (Fig. 2). Together from steel alloys to copper, titanium, tungsten 1101 Sussex Blvd, Suite 2 Blandinières, who integrated Elino into the international stainless steels, magnetic material and Fe-Ni alloys and tungsten carbides and the steel grades of Broomall, PA 19008. USA PLC Holding group of furnace manufacturers in 2010, accounted for around 83% of the market. The JPMA also Tel: +1 484 472 6863 Fax: +1 484 472 6861 our polyPOM - catalytic binder system. praised the commitment of the employees without whom Email: [email protected] stated that Invar, Kovar and titanium alloys have been the achievements of the last 80 years would not have been decreasing for several years. In the case of titanium, cost was PolyMIM has further expanded its portfolio of possible. Managing Director Dieter Schäufler additionally given as a significant factor. • polyPOM low alloys and praised his team and emphasised that companies with such www.jpma.gr.jp • polyPOM stainless steel alloys a long history have a responsible role to assume not only in business but also in society. Markets for MIM products in Japan, FY2012 Contact us to find a match for your application! www.elino.de Industrial Machine Others 20.4% PolyMIM GmbH 14.3% Information Equipment Am Gefach Sewing Machine 9.9% 1.1% 55566 Bad Sobernheim, Germany

Motorcycle Phone: +49 6751 85769-0 2% Watch Fax: +49 6751 85769-5300 3.9% Automotive 20.1% Mail: [email protected] Key or Lock System 3.3% Camera & Precision Machine 3.4% Communication Equipment Medical Appliance 4.2% 17.4%

Fig. 1 Markets for MIM products in Japan, 2012 (Data courtesy Japan Powder Metallurgy Association)

Usage of MIM materials in Japan, FY2012

Stainless Steel 63.4%

Fig. 1 Philippe Blandinières, Business proprietor of PLC Others Holding (left) with Managing Director of Elino Industrie- 7.9%

Ofenbau GmbH Dieter Schäufler Tool Steel 2.4%

Heavy Alloy 3.4% Magnetic Materials 7.1% Low Alloy Steel Fe-Ni base Alloy Submitting News 3.7% 12.1%

To submit news to Powder Injection Moulding International Fig. 2 MIM materials usage in Japan, 2012 (Data courtesy contact Nick Williams: [email protected] Japan Powder Metallurgy Association)

Dutch group targets the Specification: ADMAFLEX® Resolution µm 40 Your Preferred printing of technical ceramics Layer µm 12 100 thickness In December 2012 Dutch CIM specialist Formatec Ceramics Building speed mm/h 4-5 >10 Choice for introduced a new ceramic printing technology and since this time, states the company, the overwhelming interest in this Platform size mm 80 x 10 x 150 new technology has encouraged it to continue developments Materials - Alumina / Zirconia in this field. In order to further develop ceramic printing Metal Injection technology ECN and Innotech Europe joined Formatec’s Density % >99% initiative as partners and shortly after this the ADMATEC ® project was established. The ADMATEC project now develops Table 1 Specifications of the ADMAFLEX 80 system a wide range of printing solutions for ceramics, with mate- materials. Technical information on the process has not been Molded Parts rials, machines and process developments all addressed disclosed. within the group. As well as technology development, the ADMATEC group “It is our absolute aim to become the market leader is exploring new market segments with both the Cerafab and for printing ceramic materials. In order to fulfil this aim the ADMAFLEX® systems. By combining both technologies efficiently the group decided to invest in a Cerafab 7500 ADMATEC can supply both small and precise parts as well as from Lithoz. Adding Lithoz’s LCM technology to the project larger parts in higher volume. completely underlines our strong commitment to become a “The market seems to be discovering this technology leader in this field of expertise,” stated Michiel de Bruijcker, sooner than expected, resulting in challenging requirements Formatec’s Managing Director. on a frequent basis. Ahead lies an ambitious development plan Development of printing technologies continues within with clear milestones and deliverables for commercial and the group, with the new ADMAFLEX® technology developed technical challenges. Our current achievements, combined in-house. The main focus of the work has been to break with the Cerafab 7500 capabilities and the outcomes of the down the limitations on precision, building size and building development plan, will uniquely position ADMATEC in this new speed. Material research is also cited as a critical develop- market segment,” concluded de Bruijcker. For more informa- ment factor, along with reducing costs and broadening the tion contact Michiel de Bruijcker, Formatec Ceramics, email: total range of materials. These material developments will [email protected] not be limited to ceramics, stated de Bruijcker, adding that www.formatec.nl in the middle to long-term a pre-defined range of metals will also be developed as the process is suitable for all powder

GKN continues to make good ISO 9001:2008 Registered progress

Group results issued by GKN plc for the first six months Megamet Solid Metals, Inc. trading in 2013 showed that sales increased by 12% to £3,647 13748 Shoreline Ct. East million (up 2% on organic basis) compared with the same period in 2012. Reported profit before tax of £134 million Earth City, MO 63045 (2012: £279 million) was lower, primarily due to foreign exchange rate changes impacting the mark to market value of foreign exchange contracts. The GKN Powder Metallurgy Division sales grew by 2% to £480 million in the six month period with a trading margin of 10%, including restructuring charges. The PM Division is expected to show good year-on-year sales improvement, Fig. 1 A ceramic development study printed on ADMAFLEX® 80 although reflecting normal seasonality. Second half profit in the Division will also benefit from the absence of restructuring charges. “GKN has continued to make good progress against our strategy to grow a market-leading global engineering business. Although some of our end markets remained challenging, we continued to outperform and are reporting good underlying financial results with further benefit from last year’s acquisition, GKN Aerospace Engine Systems (formerly Volvo Aero), which is performing well. The first half met our www.megamet.com expectations and, with planned restructuring costs now behind us, we expect a stronger second half performance and [email protected] to deliver good progress in 2013,” commented Nigel Stein, Chief Executive of GKN. 314.739.4499 Fig. 2 Ceramic sensor housing produced on a Cerafab 7500 www.gkn.com

MPIF 2013 design excellence award winning parts reflect the continuing growth of MIM technology

Winning parts in the Metal Powder Industry Federation’s (MPIF) 2013 Powder Metallurgy Design Excellence Awards competition were announced at the PowderMet 2013 International Conference on Powder Metallurgy and Particulate Materials, Chicago, June 24-27. The continued growth of the Metal Injection Moulding industry is reflected in the large number of prizes Fig. 1 These MIM components are used in a sensor to measure presented to this sector in this year’s awards. MIM’s the inlet pressure of the air fuel mixture in each cylinder of a growing acceptance in the automotive industry as a passenger car engine (Courtesy MPIF) trusted manufacturing route is clear, with both a Grand Fig. 3 Stainless steel jaw made for a medical grasping device Prize and Award of Distinction being presented for MIM (Courtesy MPIF) parts in this demanding sector. The MIM process was also the manufacturing method of prize winners in the hand automatic weapon (SAW) used by the US Military (Fig. 2). tools/recreation, aerospace/military and medical/dental The device is designed to hold various size high categories. volume magazine ammunition packs securely to the gun. It extends the service life of the weapon by enabling the Grand Prize Awards soldier to repair it in the field, thus avoiding the cost of a new weapon. Automotive engine Drop testing of the firearm with the device attached Indo-US MIM Tec Pvt. Ltd., Bangalore, India, received a proved the integrity of the FSIK even while other grand prize in the automotive engine category for a sensing components were damaged. The innovative I-beam and element, a threaded port and a support ring made for webbing design allowed the parts to meet the 32–38 HRC hardness range requirement and still maintain the total weight of the kit below 3.5 oz. Moulded from MIM-17-4 PH stainless steel, the parts have >7.5 g/cm³ density, 130,000 psi ultimate tensile strength, 106,000 psi yield strength, and 6% elongation. The only secondary processing of these near net shaped Fig. 2 MIM parts for a component used in the M249 squad parts are a coining operation to the bracket in order to automatic weapon used by the US Military (Courtesy MPIF) achieve the tolerance required for the distance between the notch and the through hole, as well as tapping the Sensata Technologies Holland B.V., Almelo, the Netherlands hole to provide necessary threading. Both parts are black (Fig. 1). oxided to remove their reflective properties, a critical

At eMBe we have the products Find our products applicable for Made via Metal Injection Moulding these components are consideration for the safety of the soldier. and services to help you used in a sensor kit that measures the inlet pressure of the Ceramic Injection Moulding “shape up” your metal or air fuel mixture in each cylinder of a passenger car engine. ceramic powder. Embemould® C and Embemould® K 83 Medical/dental

The length of the threaded port creates complexity, as do the FloMet LLC/A QMT Company, Deland, Florida, USA, was Develop your products with us thin walls and fragile features, and the stringent customer awarded the grand prize in the medical/dental category by using our lab and our requirements on visual aspects add to the difficulty of for a 17-4 PH stainless steel jaw made for US Endoscopy, experience in additives design manufacture. Mentor, Ohio, and used in a Raptor™ grasping device for sintering materials. Made of MIM-17-4 PH stainless steel, the parts have a (Fig. 3). eMBe is a leading additive heat treated yield strength of 160,000 psi, ultimate tensile Made via MIM, the jaws merge into one design supplier for the ceramic and Metal Injection Moulding strength of 178,000 psi, 7% elongation, 35–40 HRC hardness that features both a rat tooth jaw and an alligator jaw, powder metal industry in Europe. Embemould® Metalfeedstocks range, and 7.6 g/cm³ density. The parts are formed close to combining the functions of a grasper and a retrieval Our services focus on product development and product net shape, with only coining and passivation required on all forceps that surgeons use to retrieve foreign objects in the innovation to continuously meet our three, plus CNC thread cutting on the port only. body during minimally invasive procedures. customers` evolving needs. This new application is estimated to save the customer The component design is enormously complex due to 50% over the cost of manufacture using alternative its small size, thin wall requirements 0.25 mm (0.010 in.), technologies. To learn more, please contact us and features required to achieve full functionality with the sharp talons and teeth at net shape. The parts have eMBe Products & Service GmbH Gemeindewald 7 Compaction and Porosity Aerospace/military >7.5 g/cm³ density, 130,000 psi ultimate tensile strength, 86672 Thierhaupten, Germany tel.: +49 8271 421988-3 Embelube® Polymer Technologies Inc., Clifton, New Jersey, USA, was 106,000 psi yield strength, 6% elongation, and 27HRB fax: +49 8271 421988-4 presented with the grand prize in the aerospace/military hardness. Only minimal secondary processing (coining to [email protected] Embemould and Embelube are registered trademarks www.embe-products.com category for two MIM parts, a U-bracket and stop used in a help maintain the alignment of the jaws) was needed, as Feedbox Support Improvement Kit (FSIK) for an M249 squad other geometries and tight tolerances were achieved in

32 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 33

The MIM design contributes to a lean operation for the customer by substantially reducing lead time through the elimination of many processing steps.

Awards of Distinction We’ve got what it takes Automotive engine to outperform our Indo-US MIM Tec Pvt. Ltd., Bangalore, India, additionally competition and we’ll won an award of distinction in the automotive engine category for a fuel control gear segment made for Bosch prove it with a FREE Limited, Bangalore, India (Fig. 5). The part goes into a TRIAL RUN IN FULL SIZE fuel control device that regulates the entry of fuel into the PRODUCTION FURNACES engine. BEFORE PURCHASE! Converted from a machined part, the gear segment is fabricated via MIM from a low alloy steel at a saving of 80% over the previous method. Moulded to net shape Elnik Systems puts more and requiring no secondary operations, the part has a density of 7.5 g/cm³, 46,000 psi ultimate tensile strength, cutting edge technology into our Fig. 4 MIM tool holder assembly for a woodworking tool used in Fig. 6 This MIM actuator is used in a tool less locking system 19,000 psi yield strength, 25% elongation and 100 HRB debind and sintering equipment fine detail carving (Courtesy MPIF) that enables quick changing of a shotgun stock (Courtesy max. hardness. Nearly three million pieces are delivered so you get more quality and MPIF) cost-efficiency out of it. annually to the customer.

Hand tools/recreation It has a 0.05 mm (0.002 in.) straightness requirement on An award of distinction in the hand tools/recreation the longer than 25.4 mm (1 in.) shaft and a tight profile category was earned by Parmatech Corporation, requirement of the curved and sloped cosmetic surface. Petaluma, California, USA, for an actuator used in a tool The part is moulded and sintered close to net shape to less locking system that enables quick changing of a 7.48 g/cm³ density, and is coined in order to achieve shotgun stock (Fig. 6). repeatability. Don’t take our word Made via MIM of a low alloy steel, the complex design Choosing MIM over casting and machining the part for it. Let the results part required the use of stepped ejector pins on the sloped provided a cost savings of 25–35%. speak for themselves. surface to allow for smooth ejection with no part damage.

Call uS today!

Fig. 5 Fuel control gear segment of a fuel control device that regulates the entry of fuel into the engine (Courtesy MPIF)

the as moulded condition. Alternative processing methods could not have achieved the part’s intricate geometries at a reasonable cost. MIM is estimated to have saved more than 60% over die casting or machining the parts. • Energy efficient, uses Hand tools/recreation less process gas, Indo-US MIM Tec Pvt. Ltd., Bangalore, India, also received electricity and handling time the grand prize in the hand tools/recreation category for • Process any metal with any binder a tool holder assembly made for Scintilla AG, Solothurn, Switzerland. The assembly that incorporates these two MIM • Process in H2, N2, Ar or Vacuum parts, a tool holder and a grip spring tensioning part, goes into a woodworking tool for fine detail carving (Fig. 4). Part complexity made MIM the obvious choice as no other technology could produce the part as an integral unit and deliver it in the needed volumes at the target cost. Made of a low alloy steel, the parts are supplied in the heat treated condition. Properties include 7.5 g/cm³ minimum density, 107 Commerce Road | Cedar Grove, NJ 07009 USA 225,000 psi ultimate tensile strength, and 200,000 psi yield strength. To overcome the possibility of distortion on the +1.973.239.6066 | [email protected] unsupported open end, the design provided supporting ribs. www.elnik.com The grip support ring was produced per print with the help of one turning operation.

SciPiVision’s market study finds strong growth for the global Powder Injection Moulding industry

A new 160 page market report batch sintering furnaces. As growth Technical Ceramics compiled by Prof Randall M German occurred, the number of manufac- From powder to finished product and Prof Sundar V Atre explores turing cells grew, but the production the continued strong growth in the ratios remained similar. Today, a typical Powder Injection Moulding industry facility has multiples of the same early CERAMIC INJECTION DRY and analyses major growth sectors production ratios. The estimated unit- MOULDING (CIM) PRESSING including healthcare, transportation manufacturing cell is reported as: and electronics. • $2.5 million in sales According to the PIM 2013 Market • 20 employees per cell Study, PIM technology accounted for • 1 mixer per cell about $1.45 billion in sales during • 5 moulders per cell Fig. 7 MIM stainless steel shuttle used in a stapling device for 2012. The major growth sectors for • 2 furnaces per cell arthroscopic surgery (Courtesy MPIF) the technology include healthcare, • 10 million parts per year per cell. transportation and electronics with Regional differences make firearm examples of PIM applications ranging Medical/dental and medical/dental dominant in North MACHINING from minimally invasive surgical tools Polymer Technologies Inc., Clifton, New Jersey, USA, America and electronic/computer/cell AND FINISHING and mobile phone components to also received the award of distinction in the medical/ phone components most significant 6 Chemin des plantes automotive sensor housings and luxury dental category for a stainless steel shuttle used in a in Asia. In Europe, consumer and 70150 MARNAY watches. Nearly 500 production firms smart stapling device for both open and minimally invasive automotive applications were found to FRANCE arthroscopic surgery (Fig. 7). support this activity around the world. Tel: +33 (0)3.84.31.95.40 predominate. It is part of a device that interacts with a disposable It is an impressive performance, rising Fax: +33 (0)3.84.31.95.49 This report provides an intense from modest sales of $6 million in Email: [email protected] staple cartridge in a computer controlled device that focus on PIM and is intended to provide 1986 when there were about 30 active provides a high level of precision, consistency, accuracy, facts for assessment of operations, www.hardex.fr operations. agility and compressive force for the surgeon using it. productivity, financial performance, The 160 page report emerges from Manufactured via MIM, the shuttle incorporates two and relative evaluation for merger- data collected for nearly 800 organisa- separate components that were previously combined via acquisition activity. This report tions associated with the PIM industry laser welding. Making this intricate, small, and lightweight serves by identifying current actors, and includes Metal Injection Moulding 0.175 oz. component presents many challenges, including customers, vendors and suppliers, (MIM), Ceramic Injection Moulding the extremely thin walls, tight radii, and true position market trends, materials, and industry Giving you (CIM), Cemented Carbide Injection geometries, especially the two leg tips, which need to concerns. Embedded in the report are the edge with Moulding (CCIM) and composites. With maintain their required strength and piercing sharpness. details on market segmentation by 15 years of history in assembling data Part properties include 7.75 g/cm³ density, 200,000 psi geography, and emerging concerns. on the PIM companies, their products, Powder Injection Molding ultimate tensile strength, 160,000 psi yield strength, The PIM 2013 Market Study is sales, powder consumption, employ- 11-30% elongation, and 82 HRB hardness. organised to show where the technolo- ment, materials, key customers, and The shuttle is formed to nearly net shape, requiring gies came from, the relative market vendors, considerable historical and only minimal secondary operations of reaming and then position in terms of production statistical trend analyses arise beyond Metal tapping the small hole, as well as providing proprietary facilities, customers, and materials Injection Molding the situational report. sintering fixtures to maintain the straightness callout for around the world, and forecasts for The data for the PIM 2013 Market the parallel walls. the future. Once current statistics are Study was derived from company www.mpif.org accumulated, prime interest emerges self-reports, on-line surveys, trade on comparative statistics. To help in the associations, conference reports, corporate and regional benchmarking, magazine articles, subscription data are included on geographic differ- Ceramic Dates announced for business compilations, facility visits, ences, showing differences in sales, Injection Molding investor reports, interviews, news materials, applications, productivity, Sintering 2014 conference in releases and other reports. and financial performance. Specific The statistical surveys show Dresden, Germany attention is given to growth opportuni- an early identification of the unit- ties and new markets. manufacturing cell for PIM. Early Sintering 2014, an international conference focussing on http://pim2013marketstudy.scipivi- Copper the latest advances in sintering science and technology facilities were typically small, with 10 Injection Molding sion.com of powder based materials, will take place in Dresden, to 20 people, batch mixing, two to three Germany, August 24-28 2014. moulding machines, and two to three The conference was last held in Korea in 2011 and next

For more information, please contact: Advanced Materials Technologies Pte Ltd year’s event is expected to attract around 300 delegates. Mr. Zulkefli Zainal Mr. David Lau No. 3, Tuas Lane, Singapore 638612 A call for papers will be issued in due course and Submitting News Marketing Director General Manager Tel: +65 6863 6551 | Fax: +65 6863 6550 To submit news to Powder Injection Moulding International contact Nick Williams: [email protected] [email protected] [email protected] | www.amt-mat.com further information will be available on the event website. +65 9068 9580 +65 9383 1082 ISO 9001:2008 ISO 13485:2003 www.sintering2014.com [email protected]

Powder Injection Moulding (PIM) offers many more creative possibilities than conventional machining processes. Complex components made from metal or ceramic can be created with internal threads, gears or undercuts and produced in high volumes efficiently and cost-effectively. When quality problems arise, it is usually the case that the mould is not optimally designed for the processing of feedstocks. In this article Hartmut Walcher and Marko Maetzig, from Arburg GmbH + Co KG, discuss the specific requirements that a PIM mould must satisfy and outline measures that can enable component quality to be significantly increased.

In the course of technical development in the area of sinter plants, quick-heating systems are The most conspicuous advantage At first glance, PIM moulds do not feedstocks has its own special rules. demanded more and more often to make production of high-performance ceramics parts more of the injection moulding of powder differ significantly from those used in In many cases, this factor is not given economic. The focus is on designing the procedure‘s steps so that continuous and plannable materials is the relatively simple and the processing of plastics. All common sufficient consideration in the injection production of high piece numbers is possible in short processing steps to achieve best economic fast series production of complex metal mould types, such as 2-platen, moulding process – and especially efficiency. or ceramic components with minimal 3-platen, sliding carriage and split where mould design is concerned. finishing requirement, in consistently moulds, are also found in powder FCT Anlagenbau, one of the leading providers of high-temperature plants, has now developed an high quality. That’s if you get it right injection moulding. However, the The mould as an error innovative plant concept with which end-contour-near sinter parts that can be subjected to a brief from the start! injection moulding of metal or ceramic source heating or cooling cycle can be produced at large piece numbers. This plant concept was first presented to a specialist audience with great success at Ceramitec 2012 in Munich. The plant, for Around 70% of all defective PIM components are caused by the mould, which a patent is pending, is available for test runs at the technical school of FCT. Error sources in the PIM process while about 15% are due to the The high-performance induction furnace FCI 600/150-100-SP was developed for production of MiM injection moulding parameters. Much parts, parts of carbide, sinter parts of ceramics or for silicon infiltration of CFC components. lower down the list of error sources are the feedstock, automation system As compared to conventional plants, this trend-setting production concept convinces with its as well as the sintering and debinding continuous multi-chamber system in module build that permits flexible adjustment. Production is processes (Fig. 1). possible in inert gas atmosphere and/or in vacuum operation. Quick heating rates by inductive In contrast to conventional injection heating permit short cycle times. Added to this are energy savings of about 30 percent - an important moulding, the cycle time with PIM is not the time-limiting factor that is deci- contribution in respect of sustainability. Lower life time costs are achieved by lower maintenance sive for production efficiency. Rather, costs both in material effort and maintenance effort. An independent parts geometry of the products the defining variable is the proportion is possible by use of crucibles as carriers. of good parts after sintering. This, in turn, depends largely on the quality For more information please contact us. of the mould and can be dramatically Fig. 1 Error sources in the PIM process: a non-optimally designed mould is by far increased by using a mould specifically the main cause of quality problems with MIM and CIM components (Image courtesy designed for the processing of powder Arburg) materials. FCT Anlagenbau GmbH Hönbacher Str. 10 Tel. +49 3675 / 7484-0 email: [email protected] D-9651538 SonnebergPowder Injection Moulding InternationalFax +49 3675 September / 7484-44 2013 © 2013web: Inovar Communicationswww.fct-anlagenbau.de Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 39 Mould optimisation for PIM | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email | Mould optimisation for PIM

tion during the design and construction wear resistant. Moulds with ceramic phases of PIM parts: inserts are therefore particularly • Functionally optimised: PIM allows suitable for components that are numerous different geometries produced in large volumes or with and additional functions can be stringent tolerance requirements. As incorporated if necessary. this ceramic is conductive, the EDM process can also be used, so that any • Optimised for injection moulding: desired contours can be achieved in the Consistent wall thicknesses and mould. minimal material use reduce component weight and costs. Harmonising mould and automation • Optimised for automation: Gentle removal of sensitive green A robotic system can remove compacts by a robotic system provides sensitive green compacts gently protection against shocks and impacts and set them down on sintering and increases part quality and process platens. reliability. Furthermore, it enables • Optimised for sintering: virtually unmanned series production Components should have sufficient and the set-down of random samples contact surface with the sintering for quality control (Fig. 4). platen, so that shrinkage is largely The more intelligently the mould is isotropic. designed for the downstream automa- Fig. 2 Snapshots clearly illustrate the flow characteristics of a CIM feedstock:jetting tion and sintering process, the simpler occurs as the material flows around a bore (Photo courtesy Arburg) PIM-optimised mould the associated gripper technology can be. Component orientation and Fig. 3 Mould inserts of erodible ceramic are wear resistant and especially suitable for In practice, often because of extremely high pressure transmission. design the relationship between the mould high volume series production (Photo courtesy H.C. Starck Ceramics) commercial considerations, a suppos- The thermal conductivity of the MIM Even more important than component cavities should therefore be designed edly lower-cost mould is employed, feedstock Catamold 316L, for example, design is the correct design of the in such a way that the injection • More good parts and fewer flaws PIM-optimised sprue design instead of using a mould designed is around 6 W/mK, whereas that of the mould to suit Powder Injection moulded green compacts can be set such as joint lines, cold displace- Due to its high thermal conductivity, for series production. However, if thermoplastic POM is about five times Moulding. Important considerations down on debinding or sintering trays as ment and distortion a feedstock cools down considerably PIM components are to be produced lower (0.14 W/mK). The value for 316L here are the increased wear due to neatly and tightly together as possible, • No temperature gradient faster than a thermoplastic. If the cost-effectively in perfect quality on a pure stainless steel, however, is over abrasive ceramic powder and the for example with single or double direct gating and the sprue channels daily basis, we first have to observe the twice as high (14 W/mK). Because • Optimum filling of cavities and temperature sensitivity and low degree spaced cavities (Fig. 5). This reduces are too long, the material begins to following basic principles: MIM materials therefore cool down component of thermal expansion of the feedstock. the handling and overall cycle time, solidify before the cavity is optimally much faster than plastics, they have • Short flow paths and short sprues, • The prototype mould must be The following measures reduce quality the required space and, ultimately, the filled. Moreover, there is more waste completely different requirements meaning savings in materials and replaced by a series production defects to a minimum: production costs. or regranulate and higher materials mould. where temperature control of the costs costs than necessary. For this reason, mould is concerned. Consequently, • Producing mould cavities from • The better the mould is designed Moulds with liquid temperature Liquid temperature control of the the component should be as large even if the geometry of components is special materials such as HIP for the application and the fewer control mould enables particularly uniform as possible in relation to the sprue identical, mould-makers cannot apply steel, carbide or ceramic. faults have to be corrected, the As PIM feedstocks are temperature temperature distribution to be and, conversely, the sprue as short as the same mould design 1:1. • Providing all components that simpler the injection moulding sensitive and can decompose even achieved. Consequently, hot feedstock possible (Fig. 6). Resolving this problem The greater density (Catamold come into contact with the under the smallest temperature compound can be conveyed into the becomes more difficult the more cavi- machine can be. 3 3 316 L: 5 g/cm , POM: 1.4 g/cm ) also feedstock with suitable surface excesses, the mould and, if possible, component and optimum filling and ties have to be filled with one shot and • Only machine operators specifi- gives rise to a major difference in flow finishes. the hot runner, should have liquid flow paths achieved, without the the smaller the component. However, cally trained in the process can characteristics. Feedstocks glide along • Positioning the mould parting line temperature control. This generally occurrence of unwanted temperature it can be achieved by using hot runners adapt the powder injection the surface, instead of adhering to it in a technically unproblematic offers the following advantages: overshoots. with liquid temperature control. moulding process precisely to suit like plastic and have a much higher location instead of on functional the relevant requirements. tendency towards undesirable jetting surfaces, to prevent problems (Fig. 2). The result is the more frequent caused by burr formation. 1 1 2 2 Feedstocks: significant occurrence of joint lines, air inclu- unsuitable sions and cracks. These flaws can be Wear-resistant mould inserts material properties cavity spacing eliminated or reduced by evacuating Hot Isostatically Pressed (HIP) PM steel 1 1 2 2 The processing of powder materials the mould, for example, or by using the or carbide is predominantly used for gained further impetus when BASF PIM injection compression moulding the processing of powder materials. introduced feedstocks at the end process. The more finely grained the structure, 1 2 1 2 of the 1980s and Hoechst launched the greater the strength and the a commercial binder system onto PIM-optimised component lower the wear. When using carbide suitable 3 4 3 4 the market. Customised feedstocks or ceramic inserts, however, attention cavity spacing design 1 2 1 2 can also be developed on this basis. must be paid to the thermal expansion The material properties of injection Components that are injection moulded of the different materials. 3 4 3 4 moulding compounds made with from powder materials must be Mould inserts of erodible ceramics a powder and binder material are designed differently from a metal part are a new development that is ideally significantly different to those of that is machined from a block, for suited to Powder Injection Moulding Fig. 4 Delicate CIM parts such as these insulators for a Fig. 5 The achievement of set-down with optimum, narrow spacing can conventional thermoplastics. They are example. Ideally, the following factors (Fig. 3). This may appear comparatively Märklin model railway require gentle handling be ensured even when designing the cavities in the mould virtually incompressible and exhibit should already be taken into considera- costly at first glance, but is especially (Photo courtesy Arburg) (Graphic courtesy Arburg)

small opening (Fig. 8). Depending on the machine type, they can achieve about twice the entry depth of a standard nozzle. The sprue length can Pressure sensor therefore be kept short. The sprue design also has a significant influence on component Vacuum valve quality. Sharp-edged, abrupt deflections lead to separation after the kink. This in turn gives rise to Pipe to the mould visible streaks on the component – the result of powder-binder separation. If we compare different sprues with Pipe to the vacuum pump an identical overall surface area (A) Fig. 6 A good example of a PIM component with an optimum design is this radius milling cutter with internal thread, but a different geometry, the following Fig. 10 With a machine equipped with pressure sensor and vacuum valve, evacuation which is series produced fully automatically in a cost and is clear (Fig. 9): can be programmed into the process. Production with a defined vacuum level provides material-efficient manner. The mould used is equipped with Fig. 8 An elongated PIM nozzle penetrates deep into the mould. • The larger the radius (r), additional process reliability (Photo courtesy Arburg) a hot runner, enabling extremely short sprues to be achieved The sprue can thus be efficiently shortened the greater the possibility of (Photo courtesy Arburg) (Photo courtesy Arburg) influencing component quality • A small surface area (O) is better Hollow silicon Big channel to than a large one and, ideally, it is seal for ejector plate vacuum pump round Verysehr good gut okgut not ok schlecht • A flat, rectangular sprue with a large surface area is unsuitable for Powder Injection Moulding.

A vented mould prevents component flaws r1 > r2 > r3 Unvented moulds can lead to air O < O < O 1 2 3 inclusions during injection moulding. A = A = A Hollow silicon 1 2 3 The result is vacuoles, cracks and incompletely filled cavities. PIM seal on parting line moulds should therefore always Fig. 7 Liquid temperature control of the mould and a hot runner Fig. 9 Sprues with identical overall surface area (A) but different be well vented. This is frequently Fig. 11 A PIM mould can be adapted for evacuation with just a few simple measures. in the production of a key fob enabled the overall weight of both geometry differ from one another considerably: the larger the achieved quite simply using ejectors A cover, sealing with hollow silicone seals and a hole to the partition are all that is sprues to be reduced from 19 to just 2.09 g radius and the smaller the surface area, the better suited is the or ventilation ducts. In this case, required (Photo courtesy Arburg) (Photo courtesy Arburg) sprue for the production of perfect quality components (Graphic however, we typically encounter a courtesy Arburg) gradual loss in quality, because the binder migrates out of the feedstock The following optional features • Large hole to the partition with Hot runners with liquid temperature near achieving a narrow temperature technology therefore takes up a lot of into the ventilation slots and, slowly enable an injection moulding machine duct to the vacuum flange control range of this kind. space and injection takes place at two but surely, contaminates the mould. to be equipped for mould evacuation If evacuation is incorporated in the Combining a liquid temperature- A very clear, practical example of points. With cold runner manifolds, The consequences are component (Fig. 10): technical planning of the mould design controlled mould with a hot runner the profitability of hot runners with the sprue weight would be 19 g – more flaws such as joint lines or pores, • Vacuum devices, comprising a from the outset, it can generally be with the same technology, which is now liquid temperature control can be than twice as much as the component which slowly increase over time. pressure sensor, vacuum valve and implemented for less than €1000. This available on the market for moulds seen in the CIM key fob, consisting of itself. It is thanks to the liquid temper- It is possible to counteract these pipes to the mould and pump extra investment is amortised very with up to 16 cavities, is an ideal a disc weighing 4.89 g set in a 2.32 g ature-controlled hot runner alone that problems, for example by using • Interfaces for vacuum devices quickly due partly to the significantly the sprue length could be reduced to a a dummy cavity as an additional improved component quality. • An “evacuation” functional minimum. The weight of the two sprues overflow at the end of the flow path. enhancement integrated in the is now just 2.09 g, corresponding to This emergency solution does not, ‘The weight of the two sprues is now control system Injection compression moulding for material savings of almost 90%. It is however, tackle the actual problem. large and thick-walled components therefore highly desirable to use a hot In all cases, the optimum solution just 2.09 g, corresponding to material Evacuation: A low-cost solution with a In order to produce perfect runner with liquid temperature control is to evacuate the mould via the major effect thick-walled or large-volume PIM for all MIM and CIM parts. injection moulding machine. Here, savings of almost 90%. It is therefore No complex special solutions or valves components with delicate or complex evacuation is programmed directly are required to prepare a PIM mould structures, the PIM injection compres- highly desirable to use a hot runner Long nozzle – short sprue into the control system and integrated for evacuation. Rather, just a few minor sion process is the method of choice. When a standard nozzle body and in the process. In this way, production and comparatively simple adaptations It is achieved by advancing the ejector with liquid temperature control’ nozzle tip is used, the mould has to be can take place at under a defined to the mould are necessary (Fig. 11): or core pull when the mould is closed. equipped with a comparatively large vacuum and according to specified Then, during injection the material • A cover for the open ejector opening to enable its temperature to quality criteria. This increases the pushes the ejector or core pull back to assembly solution. This way, the temperature ceramic ring (Fig. 7). To produce this be controlled by a heater band. This reliability of production and lengthens the end position against a programmed differences in the hot runners can be item, a complex mould with four sliding weakens the mould, increasing the maintenance intervals. With a well • Hollow silicone seal for the ejector counter-pressure in the controlled precisely regulated to within +/- 1°C. carriages from Singer Spritzguss risk of overfeed. However, specially evacuated mould, low reject rates are plate and parting line process sequence. This has the An electric hot runner comes nowhere Konstruktion is used. The mould elongated PIM nozzles only require a achievable in series production. advantage of preventing jetting, joint

lines or vacuoles, as the cavity is filled factors. The mould is an important, with leading manufacturers of mate- immediately and uniformly. if not the most important, item in the rials, moulds and furnace technology, production of good parts. Each MIM they are provided with a customised PIM-optimised injection or CIM mould should be adapted to solution. Complex turnkey solutions suit the material properties of the are achieved together with our partner moulding machine feedstock, work with evacuation and Elnik Systems LLC. The basic equipment for a Powder be filled via a liquid temperature- Injection Moulding machine comprises: controlled hot runner. Ideally, the Authors geometry of the component and • A highly wear-resistant or carbide sprues, and the downstream automa- Dipl.-Min. Hartmut Walcher MIM or CIM cylinder module tion and sintering processes, should Application Consulting PIM • A non-return valve with carbide be taken into consideration during the inserts, designed to suit the design and construction phase. Dipl.-Ing. Marko Maetzing granule size of the powder used In order to exploit the full potential, Process Engineering PIM • An elongated PIM nozzle development via a turnkey project Arburg GmbH + Co KG • A position-regulated screw with is ideal, in which a system supplier special PIM geometry adapted for accompanies the entire PIM process Arthur-Hehl-Strasse low compression and delivers an individual solution from 72290 Lossburg a single source. An important aspect in Germany • Additional nozzle heater circuit this regard is close communication and Tel. +49 (0) 7446 33-0 • Interfaces for vacuum devices. co-operation between leading manu- E-mail: [email protected] To achieve really efficient produc- facturers of moulds, injection moulding www.arburg.com tion, it is necessary to take a holistic machines and feedstocks, and between view of the Powder Injection Moulding PIM producers and the end customer. Acknowledgment process and precisely adapt it to suit a Arburg’s 50 years of PIM expertise manufacturer’s specific needs. has created a great pool of knowledge. This article is based on a presentation Customers receive advice and compre- given at the “50 Years of Arburg PIM Expertise” conference in Lossburg, Summary hensive support throughout the value- added chain, from the selection of Germany, June 2013. Powder Injection Moulding is an material and machine technology and - International Guest Speakers extremely complex topic. Component peripherals, through to smooth series quality is influenced by numerous production. Through close co-operation announced.

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44 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 45 MIM2014_A4 ad_Layout 1 8/20/2013 8:56 AM Page 1

International Conference on Injection Molding of Metals, Ceramics and Carbides Maxon Motor GmbH: FEBRUARY 24–26 • HYATT REGENCY LONG BEACH 4 LONG BEACH, CA A Powder Injection Moulding manufacturer driven by Make plans to attend precision the only international metal and powder The Swiss tradition of manufacturing high precision components Hyatt Regency Long Beach and mechanisms is alive and well at the Maxon Motor plant in injection molding Sexau, Germany. Here Switzerland’s Maxon Motor group has a PIM operation for the production of metal and ceramic components for event of the year! both in-house use and external customers. Dr Georg Schlieper reports for PIM International on a recent visit. MIM2014 CONFERENCE (February 24–26) A two-day event featuring presentations and a keynote luncheon • Advances in Component Uniformity Sexau is a small town situated in the electrical drives, in particular for facilities in Sachseln and Sexau, the pleasant foothills of the Black Forest shavers powered by batteries. Maxon group has other manufacturing • Part Selection—Best Practices in the extreme south-west of Germany, In 1967, Braun AG was acquired by facilities in Veszprém, Hungary, and • Leading Process Trends not far from the city of Freiburg and the US based Gillette Company, which Sejong, Korea. The plant in Sexau the famous wine-growing district of itself was taken over in 2005 by Procter started operations in 1989 and today it • Numerous Case Studies Kaiserstuhl. Being one of the warmest & Gamble. Maxon Motor, however, was employs approximately 400 of the 2200 • Tabletop Exhibition & Networking Reception with and sunniest regions of Germany, the taken out of this deal and to this day employees in the whole group. They Representatives from Many of the Leading area offers a high quality of living and remains in the possession of the Braun work in two or three shifts, depending a wealth of leisure activities. In winter, family. In addition to the manufacturing on the level of orders. Companies in the Field skiing in the resorts of the Black Forest ...and Much More! is popular and throughout the rest of the year the beautiful landscape attracts hiking and bicycle tours. This region is the home of Maxon Motor GmbH, a manufacturer of high preci- Optional One-Day Powder Injection Molding sion PIM components and a part of Tutorial Precedes Conference (February 24) the Swiss headquartered Maxon Motor group. Taught by Randall M. German, FAPMI world-renowned PIM expert This conference is sponsored by the Metal Injection Molding Association, The story of Maxon Motor An ideal way to acquire a solid grounding in powder a trade association of the The headquarters of the Maxon Motor injection molding technology in a short period of time Metal Powder Industries Federation group, Maxon Motor AG in Sachseln, • Introduction to the manufacturing process Switzerland, was originally established • Definition of what is a viable PIM or MIM component in 1962 as a subsidiary of Braun GmbH in Kronberg, Germany, the manufac- • Materials selection and expectations turer of high-end household electrical • Review of the economic advantages of the process appliances which were renowned for their pioneering product design. The first of Maxon’s products were shaving foils for Braun’s electric shavers. Later Visit mimaweb.org or mpif.org for complete program details and registration information Maxon focused on small and miniature Fig. 1 Maxon Motor factory at Sexau, Germany (Photo Georg Schlieper)

grinding, we try to attract profession- ally experienced people. We can then integrate the special know-how that has been built up in other companies,” stated Buurlage. The annual summer and Christmas staff parties that are organised by the company are regularly attended by Karl-Walter Braun, the main share- holder, as well as senior management at the plant. At these parties they dine with their staff and enjoy informal conversations with them, just one way by which the atmosphere in the company is kept informal. The senior management is keen to avoid any distance between themselves and their co-workers, an attitude that strengthens the ties between the staff Fig. 2 Planetary gearbox with CIM shafts and pinion gear (Photo Maxon Motor GmbH) and management. Fig. 4 A robotic arm removes green parts (Photo Georg Schlieper) Fig. 6 Catalytic debinding ovens (Photo Georg Schlieper)

Maxon’s route into PIM technology Swiss engineering is renowned for its high precision and fine mechanisms, with a prime example being watch movements, and Maxon Motor at Sexau perpetuates this tradition. Some 20 years ago the plant began to develop ceramic shafts for their drives and planetary gearboxes (Fig. 2). These were extruded from ceramic feedstock, subjected to a debinding process and finally sintered. The high precision of the shafts was achieved by subsequent centreless grinding. The manufacturing technology for these high precision shafts was developed in-house. Fig. 3 Examples of ceramic components: shafts, nozzles, pinion gears (Photo Maxon From extrusion technology it was Fig. 5 Green MIM planetary carriers (Photo Georg Schlieper) Fig. 7 Debinding and sintering furnaces for CIM parts (Photo Motor GmbH) a small additional step to Ceramic Georg Schlieper) Injection Moulding. This technology Staff and management around at the Sexau factory (Fig. 1) by opened the door for higher geometrical PIM technology at Maxon control because this has a direct effect very highly, particularly for ceramic Thorsten Buurlage, Manager of the complexity. Major investments were on part quality. Tool service life is materials. It is evident of course that Maxon has invested a lot of effort in PIM Business Unit. Buurlage joined made in CIM production equipment and Today PIM is an important part of generally satisfactory. Process automa- secondary machining of ceramics after the appeal of its plant. The company Maxon Motor in 2009 and during his operating personnel was trained for the Maxon’s portfolio of processing tech- tion is partly installed for components sintering is much more challenging is the biggest employer for miles first two years at Sexau was respon- new technology. nologies. Maxon’s PIM production area with higher production volumes. and costly than in the green state. around and highly favoured by the sible for research and development Miniature gearing requires the covers a floor space of roughly 1200 m². Robotic arms are used to remove parts MIM parts are packed in cylindrical local population thanks to the good of drives and gearboxes. This enabled highest precision, extreme mechanical Approximately ten injection moulding from the mould and place them on batches of 340 mm diameter and salaries and social benefits offered. him to become acquainted with the strength, low friction and high wear machines are in service with clamping carriers for further processing (Fig. 4). 800 mm height for debinding and Staff turnover is extremely low and manufacturing technologies applied resistance. Steel was often not forces up to 90 t, with Boy and Fanuc A batch of “green” planetary carriers sintering. Both thermal and catalytic seven apprentices are currently in the plant, including Metal (MIM) sufficient for these demanding applica- being the prevalent brands in the plant. leaving the injection moulding machine debinding processes are applied. MIM being educated in commercial and and ceramic (CIM) injection moulding. tions. With the introduction of ceramic Full electronic control of the injection is shown in Fig. 5. parts undergo catalytic debinding for technical professions. Building up and In 2011 he was appointed Production shafts and pinion gears in Maxon moulding process is essential for the Quality control procedures start 12 hours (Fig. 6), whilst ceramic parts sustaining a highly qualified workforce, Manager for the PIM sector at Maxon. gearboxes, efficiency was significantly high precision requirements of Maxon’s with regular checks on green parts require 48 hours thermal debinding as well as improving the skills of the Although the majority of workers improved and the lifetime was tripled. products. for surface defects, weight deviation time. For subsequent sintering of CIM existing employees, is a continuous are trained in the factory, the Plant “Today many manufacturers of medical Ready-mixed feedstocks from Tosoh and dimensional accuracy. Flashes parts another 48 hours is required task for the Plant Manager. In-service Manager is continuously looking to engineering products stipulate the use in Japan and BASF SE in Germany are and ejection marks are removed in the (Fig. 7). Sintering is performed in batch training is therefore an important part employ specialists in the technologies of our ceramic shafts because of their used as raw materials in Maxon’s PIM green state if required. Machining in type furnaces. While ceramic materials of the company strategy. used. “For certain operations that high operational safety and reliability”, production. Screws are wear protected, the green state is frequently applied are sintered in air, metals are sintered Powder Injection Moulding Inter- require a particularly high degree stated Buurlage. as is common in the PIM industry. Hot wherever necessary or beneficial. in a reducing atmosphere which is national was welcomed and shown of expertise, such as centreless runner moulds are standard, and great Buurlage values the expertise within composed of hydrogen and nitrogen. attention is given to mould temperature the company for green state machining HIPing after sintering is not applied.

and light weight of Maxon’s DC motors has also lead to aerospace applications such as in the unmanned space vehicle Mars Rover. Examples of the high standard of Maxon’s PIM technology are the planetary carriers shown in Fig. 9. The upper part has an integrated output shaft and the bottom one, shown in the green and sintered state, has annular toothing for the next set of pinion gears. The miniaturisation of planetary gearboxes has imposed ever increasing requirements with regards to strength, wear resistance, precision and on the Fig. 10 Miniature ceramic pinion gear (left) and planetary carrier (right) (Photo Maxon reduction of friction. The MIM steel Motor GmbH) parts, although offering a very high performance levels, were replaced step by step with ceramic shafts, pinion gears and planetary carriers. Fig. 10 shows a miniaturised pinion gear and a planetary carrier for the 4 mm diameter gearbox. A comprehensive overview of Maxon’s MIM parts for electric motors is shown in Fig. 11. In addition to Fig. 8 Selection of Maxon DC motors and drives (Photo Maxon Motor GmbH) Fig. 9 Planetary carriers with integrated planetary carriers there are pinion output shaft (top) and annular toothing gears, gears with double sets of teeth, (bottom) (Photo Maxon Motor GmbH) bushings and housings with or without annular toothing. Secondary operations are often metalworking and toolmaking services. Motors and gearboxes range from Some larger MIM parts are shown essential for the high precision of This allows Maxon to out-source the 4 to 52 mm diameter and include in Fig. 12. On the left side is the Maxon’s products. MIM parts are often manufacture, repair and maintenance gearboxes with up to six planetary housing of an automatic guitar tuner. sized after sintering in order to improve of its injection moulding tools to trains (sets of planetary gears, Fig. Fig. 11 Overview of MIM components produced at Maxon (Photo Maxon Motor GmbH) This includes six planetary gear drives specific dimensional tolerances. The local enterprises as part of a long 8). These planetary gearboxes can which serve to automatically tune the surface finish is improved as required standing partnership. In addition, the have step-down gear ratios of more six strings of a guitar independently. by barrel finishing or electropolishing. Maxon group has a Swiss subsidiary than 1000:1. The motors can run at The part on the right is an assembly The production of high precision specialising in toolmaking whose 30,000 to 60,000 rpm, sometimes even component for Maxon DC motors. PIM components is, however, only expertise can be utilised if required. 100,000 rpm. The torque generated by The ceramic products range also one aspect of Maxon’s manufacturing Together with the experienced tool the motor is scaled up according to includes some impressive components. processes. The assembling of parts designers in Sexau, Maxon Motor has the reduction of the rotational speed Fig. 13 shows a collection of ceramic into entire modules such as gearboxes an outstanding position in tool design. by the planetary gearbox, resulting in drills and scalpels. Ceramic tweezers is equally important. Assembly is The price for its high precision remarkably high torques although the are also made by Maxon. either performed in the Sexau plant or requirements is an almost complete drive motors themselves have only Ceramic spindles with a proprietary in other Maxon factories worldwide. lack of multi-cavity tooling at Maxon. relatively low torques. surface treatment for extremely low A new building is currently under Buurlage stated that for most of its Numerous applications are found friction have been developed for construction at Sexau where the products two cavities in a tool are the for these miniature drives. For precision linear drive systems. The gearbox technology will be accom- maximum. In his opinion a higher example, robots for the automatic same spindle made from steel has Fig. 12 MIM guitar tuner housing (left) and DC motor assembly part (right) (Photo modated. This, it is stated, will release number of cavities would increase the placement of electronic components a service life of 140,000 cycles and Maxon Motor GmbH) room for further growth of the PIM risk of defective parts and reduce the on circuit boards are often equipped a conventional ceramic spindle has business unit. precision of the products. This reduced with these drives. Besides their small a service life of 300,000 to 400,000 productivity in injection moulding is not size, the enormous dynamic response cycles. The special surface treatment, considered a serious drawback since of these motors is the main reason why Tool design and toolmaking however, increases the service life to injection moulding represents only they are used in this application. millions of cycles without any sign of expertise a minor portion of the total costs of Another field of application for micro wear under the same dynamic loading The high precision of Maxon’s PIM manufacturing. motors are pumps for medications conditions. A whole range of spindles products can only be achieved thanks such as insulin. The small size and is now being developed and Maxon to its long experience in tool design weight allows the patient to carry the expects this product family to substan- and quality toolmaking. The industrial Products and applications pump on the body and the extremely tially extend their ceramics business. environment in the Sexau area is char- As previously mentioned, Maxon high reduction of the motor speed Sizes will range from 2 mm, perhaps acterised by a large variety of SMEs Motor’s traditional product families serves to dispense medicine in small even as small as 1.6 mm, to 12 mm in with special expertise in cutting edge are miniature drives, shafts, spindles quantities under exactly controlled diameter. technologies, including high precision and gearboxes for micro-motors. conditions. The outstanding reliability Fig. 13 Ceramic drills (left) and scalpels (right) (Photo Maxon Motor GmbH)

produced by Maxon (Table 2) include Designation 42CrMo4 FN02 FN08 the high performance steel 42CrMo4 1% Cr-0,25% Fe carbonyl Fe carbonyl for quench and temper (Q&T) heat Composition treatment. This is used for components Mo-0,42% C-bal. Fe – 2% Ni – 8% Ni requiring high strength and ductility. DIN standard 1.7225 - - The case hardening steel FN02 is Q&T, case used for parts where a high surface Heat treatment quench & temper case hardening hardening hardness is required. FN08 can be structural structural case hardened or subjected to quench Applications toothed parts and temper. The high nickel content parts parts provides it with a high strength and Yield strength [MPa] >400 >170 >210 ductility even after heat treatment. Tensile strength [MPa] >650 >380 >380 For applications requiring high corrosion resistance Maxon offers Elongation [%] >3 >3 >15 three stainless steel grades (Table 3). PANACEA is a nickel-free steel, Table 2 Properties of typical MIM low alloy steels processed at Maxon Motor mainly used where nickel allergy is an issue, for parts that are in contact Designation PANACEA 316L 17-4PH with human tissue and for medical and dental applications. The austenitic X15CrM- Composition X2CrNiMo17.13.2 X5CrNiCuNb17.4 316L stainless steel is the standard nMoN17.11.3 Fig. 14 Miniature ceramic watch parts (white) (Photo Maxon Motor GmbH) Fig. 15 Selection of ceramic dental grade for corrosion resistant structural DIN standard - 1.4404 1.4542 parts. It has excellent corrosion implants developed by Maxon (Photo non-magnetic non-magnetic hardenable resistance, high toughness and Remarks Maxon Motor GmbH) nickel-free easily polished ferromagnetic medium strength. For higher strength Maxon’s range of PIM products corrosion corrosion PIM materials surface. It has a relatively high requirements the hardenable steel, has continuously been extended and Applications medical & dental resistant resistant toughness, is insensitive to thermal 17-4PH is recommended. improved over the years. One driving A variety of ceramic materials and high toughness high strength shock and its modulus of elasticity Finally, there is a soft magnetic force for the development of high metal alloys are processed by CIM and MIM at Maxon. The ceramic materials and thermal expansion coefficient alloy in Maxon’s materials portfolio, Yield strength [MPa] >690 >180 >660 precision micro components was the namely FeSi3. This alloy containing are zirconia and alumina (Table 1). are similar to steel which makes it Tensile strength Swiss watch making industry, where >1090 >510 >950 suitable for combinations with steel 3% silicon, balance iron, has medium a close relationship already existed. High-tech engineering ceramics are [MPa] components. Due to its excellent strength and ductility properties. Soft Fig. 14 shows the interior of a watch characterised by their high hardness Elongation [%] >35 >50 >6 biocompatibility, zirconia is preferred magnetic materials are usually used as with two miniature levers manufac- and wear resistance, temperature for medical implants. Alumina has cores of electromagnetic coils. tured by Maxon from zirconia using CIM stability, electrical isolation and Table 3 Properties of typical MIM stainless steels processed at Maxon Motor a significantly higher hardness than technology. corrosion resistance. Zirconia is the best choice for zirconia, lower toughness and lower During the last year Maxon has Commercial success One sector where Maxon certainly low friction applications and can be density. Business strategy invested great efforts in the develop- Maxon’s PIM business is growing fast. has an advantage over competitors produced with an extremely smooth The low alloy steel MIM parts ment of a new product family, namely The last year has already seen a 38% After Powder Injection Moulding is microPIM. This is not only applied dental implants made from translucent increase of external sales for ceramic technology had been developed for for drives and gearboxes, but also in zirconia (Fig. 15). The company states in-house production, the decision was Designation Unit Zirconia (ZrO2) Alumina (Al2O3) products and further double-digit medical technology. Examples of micro that the biocompatibility of the material growth of this sector is expected in the taken in 2006 to enter the open market drives with a significant commercial is excellent, all technical problems Theoretical density g/cm³ 6.08 3.98 years to come. The production area with PIM products. This strategy is potential are lightweight insulin pumps have been solved, the competitiveness Hardness HV ~ 1200 ~ 2000 has been doubled and the injection being further extended. “The focus of that the patient can carry with them of production scale manufacturing moulding, debinding and sintering our PIM technology is clearly directed and automatic pipettes. Ceramic costs has been proven and the Bending strength (4-point) MPa 800 – 1000 350 – 450 operations have now been arranged in towards high precision parts and low shafts, spindles and bearings with capacities to produce large quantities to medium quantities of up to several Modulus of elasticity GPa approx. 200 approx. 350 separate areas. Thanks to improved unparalleled low friction are Maxon’s is now being built up. At the same automated manufacturing processes hundred thousand parts per year. speciality. Dental technology is another time negotiations with a reseller with <1000 the expected strong growth will be We have a great deal of experience sector where rapid growth is foreseen a strong position in the dental implant Max. operating temperature °C depending on 1400 achieved with current staff levels, so in manufacturing planetary carriers, since the market for dental implants is business are in progress. humidity substantial additions to the workforce pinion gears and stepped gears by growing fast. These products are screwed into Thermal expansion coefficient 10-6/K approx. 10 approx. 5-7 are not envisaged. PIM, but our internal structure is not While MIM is competing with the jaw bone and support a tooth High raw material costs account suited for high volume production other well-established metalworking Specific heat @ 20°C J/kgK 550 900 replacement. They have been designed for a significant share of the total with millions of parts. This area is processes such as investment casting so that tensile stress on the ceramic Thermal conductivity @ 100°C W/mK approx. 1.5 approx. 25 manufacturing costs, at least for better served by manufacturers with and automatic CNC machining, high- is avoided. Dental implants, which the larger components, and can continuous sintering equipment,” tech engineering ceramics are unique Ohm are today predominantly made from Electrical resistivity @ 20°C 1010 1015 have a negative impact on the Buurlage stated. materials with outstanding properties cm titanium, will be offered in white competitiveness. For small parts, Consequently Maxon Motor follows which require sintering and are difficult zirconia ceramics with a light, trans- Colour white white however, if a large number of a strategy of focussing on carefully to machine. Therefore CIM is the lucent colour matching perfectly with for high secondary processing is required the selected market segments. These only option to produce many complex very rigid, highly the colour of the tooth. These products Remarks temperature raw material cost is often negligible. target markets have been defined shaped components. To fully exploit the wear resistant have better aesthetic properties than applications This is one of the reasons why PIM and investments are specifically potential of ceramic products, engi- titanium implants which may give the parts are usually very small. directed at serving these markets. neers must be trained and educated tooth a dark appearance. Table 1 Properties of ceramic materials processed at Maxon Motor

with respect to the requirements of moulding technology and tooling and and Maxon is working hard to develop ceramic design and the manufacturing three process engineers work for the these markets. technologies that are available today continuous improvement of the manu- Maxon’s customers are typically enabling the most complex product facturing processes. All developments located in Germany, Switzerland, geometries. Buurlage’s opinion is are carried out and entirely financed Austria and other European Union that design engineers are primarily by Maxon’s own resources without countries. “Close cooperation, ease of thinking in terms of metals and recourse to external funding. communication and short distances are plastics today and do not realise that essential for the successful implemen- ceramics can offer a better solution to Sales and marketing tation of our products,” commented their problem. He is convinced that the Buurlage. “Therefore our business future economic potential of high-tech Roughly half of the PIM production at relationships are concentrated ceramics is still enormous. Maxon is for internal use and requires primarily in the German-speaking no marketing activities. Marketing of countries and central Europe.” the company’s services for external Product development customers, includes the regular Customers coming with clear ideas attendance of trade exhibitions such as Author of the function of a new component Hannover Messe and various medical Dr Georg Schlieper find expert support at Maxon for the engineering shows. Where appropriate, Gammatec Engineering GmbH optimisation of their product design the PIM technology is presented on Mermbacher Str. 28 and the planning of the best manufac- exhibition stands of the wider Maxon D-42477 Radevormwald turing technology to deliver the most group. The company believes that Germany economical and technically feasible there is still a huge potential for Email: [email protected] solution. In addition, Maxon develops improvement of the awareness of this products for its in-house require- technology in many industries. The Contact ments and, thirdly, a range of finished only exception, states Maxon, is the products are developed by Maxon and automotive industry where, particularly Thorsten Buurlage marketed as standard modules via a in Europe, MIM parts are well known Maxon Motor GmbH catalogue. and the capabilities of the technology Untere Ziel 1 Five engineers work on the are widely recognised. In medical engi- D-79350 Sexau, development of new products, two neering the potential of MIM and CIM Germany design engineers develop the injection components are just being discovered [email protected]

54 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 55 APMA2013-B.pdf 1 17/01/2013 14:42

Arburg celebrates 50 years of PIM expertise with a major international conference

Injection moulding machine manufacturer Arburg GmbH + Co KG recently celebrated 50 years of involvement with Powder Injection Moulding (PIM) by organising a major international conference for customers and partners at its headquarters in Lossburg, Germany. The event attracted more than 200 delegates from Europe, North America, Asia and Africa and formed the centrepiece of what has been a year of celebrations for the company. PIM International attended the event and Nick Williams reports on highlights.

CM Arburg, a pioneer in the supply of from the effect of feedstock prepara- Center, which offered a stylish setting MY injection moulding technology to the tion on component quality and the for a varied programme that provided Ceramic (CIM) and Metal Injection complex production of micro PIM parts, a unique insight into the PIM business CY Moulding (MIM) industries, invited to cost-effective component integration worldwide. CMY industry experts to its headquarters in and production using complete turnkey In between the presentations,

K Lossburg, Germany, from June 5 - 6 systems. guests had the opportunity to experi- to celebrate 50 years of the company’s The central venue for the anniver- ence Powder Injection Moulding at involvement in PIM. sary event was the Arburg Customer first hand on seven different injection The focal point of the two-day event was an international conference attended by more than 200 invited guests from 25 countries. Sixteen presentations were made by PIM experts from Europe, Asia and North America, with backgrounds covering all areas of the PIM industry, from research to industrial production and professional associations. A broad range of topics was covered at the conference, with presentations focussing on applications, production technologies, market developments and the prospects for the future of the industry. The PIM industries in Europe, Asia and North America were reviewed, as were research and development activities. Key areas in which PIM products are used were also covered in detail, Fig. 1 On stage at the Arburg PIM conference (from left to right): Prof. Dr. Frank including the automotive, jewellery and Petzoldt, Fraunhofer IFAM; Ingo Cremer, Cremer Thermoprozessanlagen GmbH and watch-making industries, as well as former EPMA President; Prof. Dr. Kuen-Shyan Hwang, National Taiwan University; the IT and dental sectors. Presenta- Bruce Dionne, Vice President and General Manager of Megamet Solid Metals, Inc. and tions also covered all aspects of the MIMA President, along with Stephan Doehler, Arburg’s Director Sales Europe who value-added chain, with topics ranging chaired the event (Photo Arburg)

started by presenting an overview of BASF with the purpose of allowing the company’s strategy for PIM to be seen in the context of the aims of the wider business. He commented that the Catamold strategy may be hard for those outside of BASF to understand, but stated that it is important to recognise that the Catamold business unit, which includes carbonyl iron powders, is just a small part within a giant company. On the broader aims of BASF, he explained that when one talks about strategy at BASF, it has to fit within Fig. 2 Delegates at the Arburg PIM Conference , June 2013 Fig. 4 International participants network during a refreshment the company’s strategic principles of (Photo Arburg) break (Photo Arburg) seeking sustainable solutions that add value for customers. Commenting on how the BASF slogan “We create chemistry for a Fig. 6 Hans Jud, a former member of the Executive Board at Ceramtec (formerly sustainable future” could be under- Feldmühle), reflected on the production of the first CIM part in 1963. The part was stood in relation to Catamold, he produced on a Allrounder 200 S, similar to the machine shown in the foreground stated that BASF innovates to make its (Photo Arburg)

1000 Allrounders for the PIM With the new Allrounder 270 A, the industry company will be using an electric machine for the first time. In addition to celebrating 50 years uses Allrounder injection moulding To mark the 1000th PIM Allrounder, Fig. 3 Live demonstrations of MIM and CIM part production took Fig. 5 The event attracted leaders from both industry and of PIM at Arburg, the conference machines for the manufacture of its Herbert Kraibühler officially place throughout the conference (Photo Arburg) academia (Photo Arburg) coincided with the delivery of the black and white ceramic parts for presented Patrice Jaggy, Director 1,000th Allrounder injection moulding watch casings and watch straps and of Purchasing at Comadur, with a moulding machines operating in the Celebrating 50 years of PIM but also for the successful hosting of machine for the PIM sector. the anniversary machine will bring certificate as well as a hard-metal conference area. Parts being moulded The central purpose of the conference what was surely the largest interna- The machine was purchased by Comadur’s fleet of machines to 21. version of a plasticising unit. included special stainless steel buccal was to bring together leading industry tional conference yet organised that Comadur, a Swiss company that tubes for permanent orthodontic professionals to celebrate 50 years of focused exclusively on PIM technology. produces high-quality components braces, zirconium oxide drill bits for PIM development at Arburg. The story PIM International also would like to for the watch industry. Herbert the dental sector, intermediate levers of PIM processing began at Arburg in congratulate the Arburg PIM team, Kraibühler, Arburg’s Managing for the automotive industry, precision 1963 with the first ever ceramic part comprising of Hartmut Walcher (Appli- Director Technology & Engineering, hard-metal milling cutters with interior produced on an Allrounder 200 S by cation Technology Consulting), Marko explained how Comadur had threads, intricate moulded wheels for Feldmühle. This was a geometrically Maetzig (Process Development), Uwe ventured into the Powder Injection the Märklin “Krokodil” millennium complex pigtail thread guide for the Haupt (Sales/Key Accounts), Gunther Moulding industry over 20 years ago model railway locomotive, triangular textile industry. In their welcoming Ziegler (Marketing) and Stephan with the support of Arburg in order ceramic cups and a key chain with two speeches, Helmut Heinson, Managing Doehler, Director Sales Europe, on to produce chain links for watch integrated parts. Director Sales, and Stephan Doehler, the successful organisation of such a straps. With these live demonstrations Arburg’s Director Sales Europe, who major event. Initial teething problems, it was visitors could view the past develop- chaired the entire event, recounted stated, were ironed out by Arburg, ments of MIM and CIM as well as the a history of the successful develop- laying the foundations for successful latest innovations. While the mould ment of the part. During the evening A global material cooperation and joint development. for the buccal tubes was more than 30 programme, Hans Jud, a former supplier’s perspective: Over the years, stated Kraibühler, years old, the mould for the key chain member of the Executive Board at BASF restates its Arburg not only acted as a machine featured a hot-runner system and was Ceramtec (formerly Feldmühle), also supplier, but also as an application a perfect example showcasing the PIM reflected on this formative period commitment to PIM technology adviser. Comadur was industry’s latest capabilities. (Fig. 6). Martin Bloemacher, Senior Technical also one of the first customers to Guided tours of Arburg’s produc- Throughout the conference a Manager at Germany’s BASF SE, in his use hardmetal screws in order tion facility were provided in German, number of speakers and guests took presentation “The Global orientation to achieve a longer service life. Fig. 7 Taking delivery of the 1000th PIM Allrounder: Comadur’s Director of English, French, Spanish and Chinese, the opportunity to congratulate the of a PIM feedstock supplier” took the Together, the companies further Purchasing Patrice Jaggy (2nd from left) and Arburg’s Managing Director offering international visitors an Arburg PIM team not only for the opportunity to review the strategic optimised the screws, helping to Technology & Engineering Herbert Kraibühler (3rd from left) with Arburg Partners insight into how Arburg machines are company’s 50 years of contribution to development of the company’s Cata- bring them to production maturity. Juliane Hehl, Michael Hehl, Renate Keinath (from right to left) and Eugen Hehl (left) produced. the development of PIM technology, mold feedstock system. Bloemacher The company exclusively

Oil and Gas, Agricultural Solutions, because of the short cycle times and Functional Materials and Solutions, the short production life cycles.” Performance Products, and Chemicals. Recognising this was the driving Together these segments generated force behind the company’s decision, worldwide sales in 2012 of around €72 announced in December 2012, to set billion. Bloemacher stated that whilst up a new Catamold production facility 58% of sales are generated in Europe, at its Kuanyin site in Taiwan. The plant in the last five or six years the Asia will have a production capacity of 5000 Pacific region has started to play a far tonnes per year. more important role. The Chemicals Bloemacher stated, “When we division, to which Catamold belongs, consider previously stated estimations is the largest division of BASF, with of the total MIM market being 9000+ 2012 sales of €18 billion. It is based in tonnes, just this one plant in Taiwan Ludwigshafen, Germany, where BASF could cover more than 50% of the operates the world’s largest chemical/ global market today. I think that this is industrial site with more than 35,000 a strategic move.” employees. When considering current trends in MIM, Bloemacher suggested that The on-going development of 2011 is perhaps the most helpful year Catamold to look at, stating that 2012 was in Bloemacher stated that the simple aim many people’s eyes an extreme year Fig. 10 Speakers from Europe, Asia and North America presented at the Arburg PIM of the Catamold team was to help the thanks to some widely publicised new conference (Photo Arburg) PIM market grow. He explained that 3C applications. It was stated that Fig. 8 The growth of PIM 2002-2012, showing estimated annual sales (in tons) and the today the core markets for Catamold’s in 2011 more tonnage went to the from investment casting, add function Compounded Annual Growth Rate (CAGR) The MIM industry in customers are 3C, automotive, automotive sector than to any other to these and thereby bring added value Europe mechanical, and consumer, noting and although this sector was weaker to the customer. MIM is simply better.” customers more successful and that word meaning “linked” or “integrated”. that aerospace was also becoming an than in 2010, it still remains very large. The Catamold team, it was stated, In his presentation reviewing the its innovations have to be sustainable. As an example, by-products from one increasingly important market for a “The newcomer in our eyes in 2011 wants to help the MIM industry target status of MIM in Europe Ingo Cremer, “Sustainability is for us a starting point plant or process can, with the help number of customers. was Aerospace,” added Bloemacher. the investment casting market. “We Managing Director of Cremer Thermo- for new business opportunities. All we of deep integration, find usage as Looking back over the last ten years, “It looks to me like aerospace is a new want to do this through competitive raw prozessanlagen GmbH and outgoing do has to comply with these purposes, the primary raw material for another Bloemacher stated that from 2002- and very interesting playground for materials prices. This is the reason President of the European Powder including Catamold.” product or application in another 2012 PIM had a strong Compounded the MIM community and I see many why we recently introduced two new Metallurgy Association (EPMA), told Bloemacher explained that the division. The Catamold project itself, Annual Growth Rate (CAGR) in the companies going in the aerospace Catamold product lines that should delegates that more than 50 compa- company’s structure has been shaped stated Bloemacher, was started range of 10 to 12%, in some years even direction.” enable customers to compete against nies, from component manufacturers to allow an integrated approach to more than 25 years ago with a view to more (Fig. 8). He added, “We believe In terms of materials, it was stated other technologies. These grades we to raw materials and equipment manufacturing, research and an developing applications for its carbonyl that this growth rate will go on. The that stainless steel today dominates have named K. The Catamold portfolio suppliers, were active in Europe’s MIM overall management philosophy. iron powder. 2012 column is probably much higher the MIM industry. This, commented will further be expanded to push industry. This philosophy, together with the The Catamold and carbonyl iron than indicated here, we are just not Bloemacher, is a surprise if we look the technology to industrialisation. “Today in Europe MIM is a well- maximum integration of infrastructure, powder business unit is just one of too sure right now about how much back over the last 25 years, where This is a simple statement, but there established industrial sector with a processes, energy and waste manage- around 80 strategic business units, higher.” historically the use of low alloyed steels will be more new grades to come to wide variety of different applications ment, is known as Verbund, a German all of which fit into five segments; In terms of regional trends, based on carbonyl iron powder, the extend our competitive price strategy, and markets. Unlike other regions, Bloemacher explained that today workhorse of feedstocks for so long, with these being available on a real we cannot break the markets down to approximately 59% of the MIM market dominated the industry. industrial scale.” a dominating sector, like 3C in Asia. is in Asia, with North America and Concluding, Bloemacher stated, Even in the recession in 2009 we had Europe each now accounting for Working with producers to grow MIM “Catamold wants to stay as the leading continuous growth, so we could say 20-21%. “When we started 25 years Considering the future opportunities supplier of feedstock in the PIM world. that the industry is crisis-resistant,” ago we were all looking to America. for MIM, Bloemacher asked “Where is We will further invest in Catamold. We stated Cremer. At that time the initial technology was the competition? I see this in invest- have invested in a new service labora- Although Europe accounts for one made in America. They had the key ment casting. Yesterday we heard tory in Shanghai with new staff and fifth of global MIM production in tonnes people in the industry and that’s where about additive manufacturing and new equipment. We are right now at per year, Cremer stated that in terms the market was. Today it is completely liquid metals, but I personally think the start of an investment offensive at of raw materials and production equip- different.” that this is for the future. We have to BASF and we will invest further in the ment for MIM, Europe enjoys a world Bloemacher explained that whilst deal with the competition today, and Ludwigshafen site where we have new leading position. tremendous growth has taken place in today the competition is not amorphous sintering systems installed, as well the general engineering, automotive, metals or additive manufacturing, our as a new Arburg injection moulding MIM applications in Europe and 3C sectors the market remains competition is investment casting.” machine. BASF is committed to the Cremer explained that the market for very fragmented. He stated, “In Asia “What can investment casting do industry and we are committed to the MIM products was not static but rather the growth is achieved by a few giant that MIM can’t? If we look at a part in market. We are ready to produce as evolving, with new sectors turning companies and hundreds of small ones the range of 40 mm or 40 g I am sure much feedstock as needed. Our focus to MIM as the technology continues and 3C market is characterised by that MIM can compete better on cost will be on industrial scale production to advance. Comparing the 2010 and very short reaction times. We therefore and quality. MIM can do so much more and processes and we will help our 2011 estimations of MIM markets in recognised that as a raw materials than investment casting. In my opinion customers to be more competitive Europe, the most striking changes Fig. 9 Delegates in the Arburg PIM laboratory (Photo Arburg) supplier it is a must for us to be there this is where the future of MIM lies, through the development of new were the growth of the aerospace and we just have to take simple parts away grades and systems.” medical sectors (Fig. 11). Aerospace,

than in 2010 because of strong growth tools, injection machines and furnace in other sectors. He stated that MIM equipment. It is often used in high-tech MIM Markets in Europe 2010 NorthNorth American American MIM MIM materials: materials: still has the potential to grow within areas and for very valuable parts such PartPart shipments shipments by weight by weight Mechanical the automotive sector thanks to the as heat sinks, micro gears, surgical 14% Automotive opportunities that MIM technology can instrument applications, implants StainlessStainless Steel Steel Medical 43% 50.9%50.9% 13% offer designers. These were identified and blenders. To enter this market as cost efficiency, the ability to lower a you must understand its special Soft MagneticSoft Magnetic Alloy Alloy 6.8% 6.8% component’s weight thereby reducing demands - these are totally different energy consumption, the ability to to conventional 3C parts or automotive TungstenTungsten Alloys Alloys IT combine various functions into a applications.” 1.3% 1.3% 4% complex net-shape component and the Cremer also identified the simula- ability to deliver products with a high tion of the MIM process as a key Consumer quality appearance. Sensor compo- technology trend, “As in other industry Steel Steel OtherOther 36.8% 4.2% 26% nents and housings were identified as sectors simulation is becoming more 36.8% 4.2% application areas for MIM with growth and more important. It can help for potential, including numerous engine, faster development, feasibility studies MIM Markets in Europe 2011 NorthNorth American American MIM MIM materials: materials: chassis and safety devices, as well as and will help towards cost savings. We PartPart shipments shipments by pieces by pieces Mechanical Aerospace major opportunities in the next genera- can say that simulation software is 18% StainlessStainless Steel Steel 8% tion of green vehicles. today mature. For sure it’s not without 56.6%56.6%

Medical Automotive “So the car industry will be a stable hiccups, but it is a must have for PIM 23% 23% business partner for MIM, maybe not part development.” with the highest margins, but stable,”

concluded Cremer. Global MIM furnace capacity installed Soft MagneticSoft Magnetic by Cremer Alloy, Alloy,3.9% 3.9% Technology trends In his presentation Cremer also shared TungstenTungsten Alloys Alloys Cremer stated that 2-colour MIM with delegates some data on MIM 2.1% 2.1% presented opportunities for the continuous sintering furnace capacity Consumer Steel Steel IT OtherOther 13% 32.4%32.4% 15% industry as no other manufacturing as installed by Cremer Thermoprozes- 5% 5% process could produce material sanglagen GmbH, the leading global combinations as effectively as MIM. supplier of continuous MIM sintering Fig. 11 The evolution of Europe’s MIM markets, 2010-2011 (data EPMA) Examples of 2-colour combinations furnaces, between 1992 and 2013. This North American MIM markets: were given as magnetic/non-magnetic, data was given with a view to helping Part shipments by weight

Cremer stated, had in 2011 grown to tions grew from 13% of the market in ceramic/metal, hard/tough, and dense/ the industry gain a better under- Other Automotive 4.4% an estimated 8% of the total European 2010 to 23% of the market in 2011. porous. standing of global production capacity. General industrial 12.5% 16.1% Dental MIM market, whereas in 2010 it did Cremer cautioned, however, about MicroMIM (µ-MIM) was also Table 1 shows that the total capacity Defence/Aerospace 2.9% 1.4% not even warrant its own listing, being negatively interpreting the automo- highlighted by Cremer as an important of MIM-Master furnaces worldwide Medical included with the mechanical sector tive industry’s falling share within niche in MIM. “Naturally the tonnage is stands at just over 6000 tons of Telecomms 10.5% 1.3% that covers, amongst other markets, Europe’s MIM markets, stating that low, but it has the highest value added feedstock per year, with Asia being the firearm components. Medical applica- in 2011 it only appears to be weaker figure. The technology requires special largest market. The annual capacity of each type of Cremer’s MIM-Master system is based on a MIM 316L or 17-4 MIM-MASTER MACHINES INSTALLED 1992-2013 Electronics PH cycle, processing a 25 g part for 300 8.6% Total MIM-Master 4 6 8 6XL 8XL 8XXL 8XL-Twin days, 24 hours a day over three shifts. Firearms machines 42.3% Capacity in tons/year of 73.33 110 146.67 157.83 210.43 255.07 420.87 The past, present and feedstock future of the North Fig. 12 North American MIM parts shipments. Top, materials by weight; middle, Europe 1 1 7 0 5 0 0 14 American MIM industry materials by pieces; bottom, MIM markets, part shipments by weight (Based on data obtained in a MIMA survey) America 0 3 3 0 1 0 0 7 Bruce G Dionne, Vice President and General Manager at Megamet Solid in California in the early 1970s. The In 1980 the patent for the MIM Asia 5 2 4 2 3 1 1 18 Metals, USA, and President of the developments by Ray Wiech, Ray process was awarded to Wiech, who 6 6 14 2 9 1 1 39 Metal Injection Molding Association Millett, Karl Zueger and Peter Roth then left Parmatech to form Witech. Annual (MIMA), brought a North American at Parmatech, founded in 1973 to Parmatech and Witech then proceeded MIM-Master 4 6 8 6XL 8XL 8XXL 8XL-Twin capacity/ perspective to the conference with his commercialise the process, led to the to license the technology and, stated tons presentation “The past, present and earliest MIM parts finding applications Dionne, MIM was spread around the Europe 73 110 1,027 0 1,052 0 0 2,262 future of the North American MIM in the US aerospace and defence globe faster than ever could have been industry.” industries. One application example, a realised without a licensing strategy. America 0 330 440 0 210 0 0 980 Whilst the focus of the conference’s rocket engine thrust chamber injector, Many successful new applications Asia 367 220 587 316 631 255 421 2,796 celebrations was 50 years of PIM, from 80Cb-10W-10Ta, was in 1979 the followed, with early examples including 440 660 2,053 316 1,894 255 421 6,039 linking to the production of the first first MIM part to win an MPIF Design components for typewriters, dot matrix CIM part by Feldmühle in 1963, Dionne Competition Award and led to a surge printers, disc drives and firearms. Table 1 The total capacity of MIM-Master furnaces worldwide, based on a MIM 316L or 17-4 PH cycle, processing a 25 g part for 300 started his presentation by outlining in interest in this revolutionary new In 1985 fewer than ten companies days, 24 hours a day over three shifts the development of MIM technology technology. were known to be supplying parts to

customers in North America, however the sizes of their workforce, however tion runs that are required to serve industry in supplying the 3C sector. parts. As examples, Prof Hwang stated within a decade the number had tripled Dionne added that as in other world auto makers. The widely reported Trends in MIM in Taiwan were that there have been seven versions of to more than thirty companies. regions it is hard to find talented and surge in demand for firearms has highlighted based on data gathered the iPhone in six years, and in only two well educated employees to help meet driven MIM sales higher in recent years for Prof Hwang’s presentation at the years ten versions of the Nokia Lumia The North American MIM landscape the growing demand for MIM products. but Dionne cautioned that the bubble PM2012 World Congress, Yokohama, and sixteen variants of HTC phones. today In terms of business approaches will eventually burst, “The unfettered 14-18 October 2012. It was stated that Each phone, he stated, typically comes There are currently around fifty compa- and technological innovation, Dionne growth of the industry is not sustain- as of August 2012 the Taiwanese MIM with new or redesigned parts and it can nies supplying parts to customers or in stated that ISO/TS certifications are able over time - the demand spike industry consisted of 32 MIM parts be very difficult to predict the commer- captive production in North America. common place, lean manufacturing is based upon politics and fear and producers operating 747 moulding cial success of each model. Dionne explained that of the current principles have been widely adopted, eventually politics change.” machines, 145 vacuum furnaces, and “With such short part lifetimes, MIM parts fabricators in North America Six Sigma principles are commonly It was anticipated that as the 14 continuous furnaces, consuming projects that die before production, Fig. 13 An example of typical low material most are located in the US, with a few applied and large scale production industry continues to mature there will an estimated 1500 tons of powders order cancellations or reductions, and usage in a small MIM part in Canada and Mexico. The total North capacity is growing, reflecting a be a continued development of MIM in 2012, 55% of which were stainless big differences between customer American market is estimated to be strong business focussed approach. materials for new applications, a focus steels. A full review of the survey forecasts and actual shipments - this develop products and a process for worth US$300-350 million with the The use of simulation packages is on higher efficiency production as results was published in the December sector is full of challenges for MIM mass production in an ever more timely sizes of operations ranging from fewer also common, as are state of the art part of a drive towards higher profits, 2012 issue of PIM International (Vol. 6 parts producers,”stated Prof Hwang. and cost-effective way. Continued than 20 employees to more than 300. moulding practices such as hot mani- and strong growth opportunities for No. 4, p. 45-50). expansion for the industry also requires Current growth estimates recently folds, unscrewing cores and automated implantable MIM alloys. Materials utilisation and recycling large investments in capacity for what reported by members of the Metal part handling. Looking to the sources of competi- Issues unique to IT and 3C MIM parts When reviewing the production of may be high risk short lifetime parts. Injection Molding Association were in tion for the industry Dionne stated that When considering issues that are small parts for the 3C sector particular Finally, it was stressed, the industry the region of 15-20% per year. Looking to the future these were not only from conventional unique to the production of MIM attention was paid to the challenge of needs to ensure a future supply It was also stated that there Automotive applications are increasing investment casting and machining parts to the 3C sector Prof Hwang efficient material usage and recycling of highly skilled and hardworking are strong indicators that MIM in North America, suggested Dionne, industries, but from super high stated that location and delivery considerations. The component in engineers. parts makers in North America are with several companies having the performance thermoplastic materials were of high importance. It was for Fig. 13 was presented as an example increasing both capital spending and capacity to support the large produc- such as PEEK and Kevlar filled nylon, this reason, he suggested, that the of just how much excess material as well as new technologies such as largest four Taiwanese owned MIM (highlighted in red) can be generated in An Asian perspective: Additive Manufacturing and the liquid producers all have plants in China. the production of small MIM products. Meeting the demand for Small Part Large Part metal injection moulding of amorphous The primary benefits, he explained, Prof Hwang explained the two ultra high volume small No. of cavities 16 2 alloys. were down to being closer to the recycling methods used in the MIM manufacturing centres, thereby industry. In the first method 100% of all MIM parts Part weight 0.064 g 117 g An Asian perspective: reducing delivery times, and having scrap is recycled without the addition Taiwan Powder Technologies Co. Runner + sprue weight 58.3 g 9.7 g subcontractors located close by. of unused feedstock. The disadvantage Ltd. (TPT), represented by the Understanding MIM for Quicker communications relating to of this method, it was stated, is that the Material use/cycle, % 1.7% 96% company’s President Jonathan Tsou IT applications design and engineering developments, rheometry of each feedstock deterio- and its General Manager and founder Table 2 Data on the two parts used for a study of material usage and recycling methods inspection methods and inspection rates as recycling progresses. Dr Y C Lu, offered further insight into In his presentation “MIM for IT Applica- gauges were also identified as factors. The second recycling method MIM production for Asia’s 3C sector tions” Prof Kuen-Shyang Hwang, from Product development discussions, he involves mixing 30-50% waste material with the presentation “Unique solutions METHOD 1: Feedstock recycled 100% w/o replenishing the Department of Materials Science added, were also far more effective with new unused feedstock. It was for small MIM Parts.” and Engineering at the National Small Part Large Part face to face, especially considering suggested that the drawback of this Founded by PhD students from the Taiwan University, Taiwan, reviewed Material use/cycle, % 1.7% 96% the typically high number of revisions method is that some feedstocks may National Taiwan University in 2001, TPT the historic development of the use of associated with the development of cell eventually contain materials that have has grown under Dr Lu’s guidance into Utilisation rate after 3 cycles MIM parts in 3C applications, identi- 100% phone parts. been recycled more than ten times. one of Taiwan’s largest MIM producers. or 8,546 parts fied current trends and challenges, The volumes of parts required for Following investigations into the Additional production facilities were and discussed issues surrounding Utilisation rate after 9 cycles many applications in the 3C sector production of the two parts, one opened in mainland China in 2012 and 14.5% the efficient use of feedstock in the or 2.27 million parts also posed challenges as quantities small part (0.064 g) and one large today the company operates 99 injec- production of extremely high volume Utilisation rate after 15 cycles can be extremely high. Not only do part (117 g), Prof Hwang compared tion moulding machines, 21 vacuum 23.0% miniature components. or 3.59 million parts strategic investments need to be made the materials utilisation data for furnaces and two Cremer MIM-Master Prof Hwang explained that despite in MIM production facilities, but also both feedstock recycling methods. continuous furnaces, the first of which the current explosion in the growth Table 3 Materials utilisation for feedstock that is continuously recycled without the in the extensive facilities required for Calculations were based on one ton of was installed in 2007. In 2011 the of MIM parts for cell phone applica- addition of new material finishing, polishing and final inspection. feedstock. Table 2 shows basic part and company celebrated the milestone of tions, the use of the technology by To give an insight into the recent levels production data, whilst Tables 3 and 4 shipping more than 200 million parts. this industry is not new. A number of METHOD 2: Feedstock replenished with 50% new materials after of investment in MIM by Taiwanese show the final materials utilisation for Tsou told delegates that the very older application examples were given, every 4 cycles owned companies, Prof Hwang stated both recycling methods. high volume production of small parts including the Nokia 8800 that dates Small Part Large Part that 182 new moulding machines were It was suggested that much could for the 3C sector pushed MIM tech- back to 2005 and the original iPhone installed between August 2011 and July still be done to improve materials utili- nology to the extreme, but there was a Method 1 Method 2 Method 1 from 2007 in which the Apple logo on 2012. sation in small components through growing requirement for such parts to Material use/cycle 1.7% 1.7% 96% the reverse was a polished MIM part. It was stated, however, that the the use of more sophisticated tooling serve the demand for components for Prof Hwang explained that whilst cell Utilisation rate after 4 cycles 6.7% 6.7% risks to new investors were high. Not designs with shorter runners, the ever smaller, lighter and more complex phone applications have hit the head- only is there a continuous threat from optimisation of cavities, and moulds electronic devices with increased Utilisation rate after 8 cycles 13.0% 10.0% lines in recent months, IT applications competing technologies, but a new incorporating hot runner systems. functionality. including parts as diverse as hinges, Utilisation rate after 12 cycles 18.9% 13.2% operation needs to be able to secure Concluding, Prof Hwang stated The 3C sector’s primary character- fibre optic connectors and computer a good source of technical staff and that the 3C industry is important for istics include extremely high volumes, Table 4 Materials utilisation for feedstock that is recycled with the addition of 50% new security systems have all contributed labour. There is also the constant chal- the MIM industry and vice versa. The which can be in the tens of millions material after every 4 cycles to the huge success of the Asian MIM lenge of the short lifetime of cell phone challenges for the future lie in how to of parts in a week at peak, fast design

and prototyping cycles, high-precision latches, hooks, shields etc.). Such components and that the process was and low variability finished parts for parts typically weigh 0.3 to 1 g and are significantly more economical than efficient automated assembly, as well between 2 and 10 mm in length. machining, with excellent versatility for Developments in PIM as fast production ramp-up times, The primary benefits of using MIM surface finishing and good corrosion short product life cycles, and high for such high volume parts were given and abrasion resistance. uncertainty as to future demand. as design flexibility for complex forms In terms of determining what materials and processing at Tsou stated that MIM parts for 3C and significantly superior mechanical applications succeed in being produced applications typically fall into three properties compared to plastics – with by MIM, Tsou stated that the key factors categories; mechanical components the differences in mechanical proper- were speed of part development, speed PowderMet 2013 Chicago (fasteners, hinge, pivot level, fixtures ties being particularly apparent in of production, production volumes and and holders etc.), cosmetic parts small scale products. Tsou stated that cost. Technically, the future challenges (logos, bracelets, covers etc.) and MIM was the most effective route for for producing such high volume small, electromagnetic parts (connectors, the high volume production of such thin walled and complex shape parts will require ever better binder formulations and mould designs. High volume Cycle Time Capacity Cavity Number (sec) (pcs/day) production also required high cavity moulds (Table 5), however whilst such Although the increasing popularity of MPIF’s spring 4 40 7.2K moulds reduce the number of injec- Metal Injection Moulding conference has, to some 8 40 14.4K tion machines, there is a significant extent, diminished the coverage of the technology at increase in the complexity and cost of 16 40 28.8K moulds and production. its international all-subject summer conference, there 32 40 57.6K Elaborating on the challenges in remained more than enough content at PowderMet 2013, producing small MIM parts for the 3C Table 5 Using multi-cavity moulds enables the rapid production of components for the held in Chicago, June 24-27, 2013, to capture the attention 3C sector, but there are drawbacks in terms of tooling and production costs sector, Tsou stated that an automated, flexible production facility was essential of MIM devotees. Dr David Whittaker reports for PIM International. to be able to cope with orders that can change from a trough to a peak in a very short period. Quality control and process monitoring of all aspects of the process, from feedstock production to injection moulding and sintering, was also essential in order to achieve the necessary high uniformity and low batch-to-batch variation demanded by Close-coupled gas fluid dynamics (CFD) models have been and crossed the neutral zero region. end-users. atomisation of fine powders used to study these upstream effects. This was also observed in experimental Echoing the presentation by Prof Models have been built based upon an testing. Although the positive back Hwang, Tsou stated that reducing CFD study on flow characterisations industrial-scale unit (a 300 lb experi- pressure can effectively overcome the runner-to-part ratio through better in the upstream of gas atomisation mental facility at the company’s R&D metal head, hold the stream and stop mould design and binder systems was process Department). Free expansion flow field also important. In an update on work reported by the and pressure distribution at different same authors at PowderMet 2012 and injection conditions were reported. Melt Areas of future development covered in the September 2012 issue stream has also been studied using the of Powder Injection Moulding Interna- Fig. 14 Balancing conflicting objectives in the extremely high volume production of Looking to the future, Tsou explained volume of fluid (VOF) method. tional, Guanghui Yu and Gregory Del Three different types of nozzle small MIM parts that a further move towards fully automated production was a key goal. Corso (Carpenter Technology Corpora- setup were included in the model- An advanced automated production tion) presented the latest results in ling research. Modelling results cell for extremely small parts was their modelling of the close-coupled have shown that a Type I nozzle, in shown (Fig. 15). In terms of alternative atomisation process. aspiration pressure style, shows a very processing technologies, the company Gas atomisation is a sophisticated typical stagnation area several nozzle is also developing what it calls High bi-fluid process. Highly pressurised diameters away from the tip. It also Performance Powder Metallurgy (HPM) gas is released very tightly around the shows a small scale pressure wave which uses powder grades similar to coherent melt stream. Both streams, and a so called pressure punch on the those found in MIM, combined with with extremely high speed and central axis and close to the tip (Fig. 1). a powder pre-treatment and then a temperature, result in unparalleled High pressure in the gas punch can pressing step in a PM powder press challenges in accurately measuring squeeze the melt to the side and form to create small green compacts that and fully understanding the process. the typical melt film curtain and hollow can then be sintered using a similar Flow behaviours upstream are more centre in a close-coupled process process cycle to MIM. The company difficult to investigate due to the nature (Fig. 2). also sees value in expanding from of the harsh environment and limited The type II nozzle had a smaller Fig. 1 CFD modelling of near field solely an OEM (Original Equipment space. However upstream flows play tip and extension, and was in back pressure distribution. A pressure punch Manufacturer) to an ODM (Original important roles in the atomisation pressure style. The modelling (Fig. 3 plays an important role in the primary Design Manufacturer). process in terms of efficiency, consist- and 4) showed that back pressure fully break-up phase. From presentation by ency and reliability. occupied the nozzle tip area. Nozzle tip G Yu et al. at PowderMet 2013 (Courtesy Fig. 15 Moving towards full process automation at Taiwan Powder Technologies In the reported work, computational pressure went from negative to positive MPIF)

Fig. 8 Image of the “skull” remaining Fig. 9 SEM images of as-atomised powders in various size ranges, showing their spherical after atomisation, indicating complete nature and satellite-free surfaces. From presentation by A J Heidloff et al. at PowderMet Fig. 2 Modelling results of the Type I nozzle in the high pressure Fig. 4 Modelling results of Type II nozzle at the high pressure emptying of the pouring nozzle. From 2013 (Courtesy MPIF) condition. From presentation by G Yu et al. at PowderMet 2013 condition. From presentation by G Yu et al. at PowderMet 2013 presentation by A J Heidloff et al. at (Courtesy MPIF) (Courtesy MPIF) PowderMet 2013 (Courtesy MPIF)

of close-coupled atomisation and Two multi-stage reaction halos AES (Atomic Emission Spectroscopy) downstream controlled multi-stage were implemented downstream of the were used to characterise the resulting

passivation of titanium aluminide. atomisation using O2 and NF3 reaction powders. Chemical granular method of Fine powder production of titanium species. analysis indicated an oxygen-rich layer aluminides was made possible by a Ti-48Al-2Cr-2Nb (at%) was thickness of 4.5 nm and fluoride-rich prototype close-coupled gas atomiser, atomized using the prototype CC-GA. layer of 2 nm. specifically designed for titanium, and Complete emptying of the superheating XPS analysis was conducted on provided powder with sufficient surface pouring nozzle was area to enable downstream controlled observed during passivation. atomisation and in the The halogen species, fluorine, was final remnant skull Fig. 3 Modelling results of Type II nozzle at the low pressure Fig. 5 Modelling results of the Type III nozzle at high pressure introduced into the passivation reaction (Fig. 8). As-atomised condition. From presentation by G Yu et al. at PowderMet 2013 condition. From presentation by G Yu et al. at PowderMet 2013 gas to provide a reservoir (once the powders were very (Courtesy MPIF) (Courtesy MPIF) powder was consolidated) for improved spherical in nature oxidation resistance of consolidated and were consistent the flow, it was observed that a back Two types of tapping setup were Further potential modelling parts. with previous pressure nozzle can work continuously also studied. The tundish, inducing research was discussed and this will A methodology for halogen (e.g. prototype atomisation without trouble. It has been proposed pipe and the ceramic orifice remain include the areas of atomisation by fluorine) introduction into titanium runs (Fig. 9). that the melt film curtain around the unchanged in the two variants, but elevated temperature gas, the effect aluminides for improved oxidation Multi-stage nozzle rim plays an important role in tapping location and tapping angle of supplementary gas in powder resistance was described. Fine, high passivation target sustaining the continuous process. both varied from Type A to Type B. Both production and anti-recirculation and surface area powders are ideal for low temperatures The type III nozzle was introduced tapping spot and angle were more optimised tundish design in reducing temperature reactions with a halogen were 400-600°C to simulate this metal film. It turned moderate in Type B. tapping disturbance of the melt steam. species for process control. and 300-400°C for out to show very similar effects to an Non-optimised tapping positions Volatility of fluoride species the oxidation and aspiration style nozzle (Fig. 5). can detrimentally cause stream inter- Evaluation of titanium aluminide motivated the use of a more stable fluorination reactions, To some extent, it was confirmed ruption or wiggling (Fig. 6) due to large close-coupled atomisation and multi- oxy-fluoride species in reaction with respectively. that a small segment of metal film air bubbles scrolling down through stage passivation titanium aluminide powders. For Chemical granular Fig. 10 Semi-quantitative chemistry from XPS depth profile will significantly change the working the orifice. On the other hand, a good In a second paper in this session, a multi-species reaction layer, a analysis, XPS (X-ray data showing change of oxygen and fluorine with increased mechanism of certain nozzle setups tapping position (Type B) can eliminate Andrew Heidloff, Joel Rieken, Iver multi-stage passivation process was Photoelectron depth. From presentation by A J Heidloff et al. at PowderMet and play a critical role in sustaining the the worst scenario. Melt stream is Anderson and David Byrd (Ames integrated into the atomiser system. Spectroscopy) and 2013 (Courtesy MPIF) continuous process. more steady and consistent (Fig. 7). Laboratory) reported on an evaluation

Fig. 6 Two-phase modelling results of the tapping process Fig. 7 Two-phase modelling results of the tapping process with the Type A set-up. From presentation by G Yu et al. at with the Type B set-up. From presentation by G Yu et al. at Fig. 11 AES depth profiles of three sets of five particles to assess multi-layer thicknesses. From presentation by A J Heidloff et al. at PowderMet 2013 (Courtesy MPIF) PowderMet 2013 (Courtesy MPIF) PowderMet 2013 (Courtesy MPIF)

heterogeneous, even after sintering at high temperatures and long times, as was the case in previous studies reported by these authors. In this particular study, the micro- structural aspects of the compacts were changed by altering the characteristics of the Ni powder used, such as particle size, shape and distribution. The most impressive properties were attained in quenched and tempered compacts containing 6 wt% fine Ni powder (mean particle size of 6 µm). This material generated a “ultrahigh” tensile strength of 2040 MPa coupled with an elongation of 8.1 % (Fig. 12). Fig. 15 Results of uniaxial deformation simulated by the FEA models. From Fig. 12 Effect of (a) Ni particle size and (b) sintering conditions on UTS and elongation of quenched and tempered Fe-6Ni-0.4C The state of the Ni dispersion presentation by W S W Harun et al. at PowderMet 2013 (Courtesy MPIF) compacts. From presentation by W S W Harun et al. at PowderMet 2013 (Courtesy MPIF) throughout the matrix was deemed to be the key factor in determining these Global Services) provided an analysis of unexposed and exposed powders. mechanical properties. HIP densification of MIM the combined MIM plus HIP processes Surface chemistry was consistent In order to understand how the parts using metallurgical principles. across the characterised powder size microstructure results in these high MIM processing techniques have From this analysis, it would appear range. Exposure resulted in slight mechanical properties, the authors evolved to the point where parts that a practice of pursuing maximum oxygen enrichment at the surface, developed a 2D finite element model makers consistently produce a high sintered density followed by HIP is, but was maintained after long term based on the spatial distribution quality PM part having three dimen- possibly, not optimal for full densifica- exposure. obtained experimentally. sional complexity with as-sintered tion. This paper examined the relation- Surface layer thickness from XPS The existence of a higher Ni region density levels that are 96% - 98% of the ship between MIM process variables was determined at 3.5 nm and 1.5 surrounded by the matrix region in theoretical density for a given alloy. and HIP densification, identifying nm for the oxygen- and fluorine-rich the Fe-6Ni-0.4C compact using fine Ni In cases where all porosity must be several key areas where current layers, respectively (Fig. 10). Surface powder was observed experimentally. eliminated, Hot Isostatic Pressing (HIP) practices, both in MIM and HIP, might layer aluminium compounds with To implement this structure into the is used as a post-sinter treatment. be modified to yield improved response oxygen and fluorine were produced in numerical model, the experimentally Commercial HIP operations to post-sinter HIP. the consolidated alloy based on XPS observed heterogeneous microstruc- often have a collection of proven While metallurgical theory indicates Al2p binding energy shifts. ture had to be simplified. From detailed Fig. 13 Schematic diagram of multi-regional Ni concentration within Fe-6Ni-0.4C processing conditions for the various that grain growth could have a negative AES depth profiles confirmed the Ni element topographies derived from compacts using fine (6µm) nickel powder. From presentation by W S W Harun et al. at alloys handled by MIM parts makers. effect on HIP densification, other presence of distinct surface films of image analysis software, average Ni PowderMet 2013 (Courtesy MPIF) However these standard HIP condi- factors, such as the concentration of oxygen- and fluorine-rich components. peak in the higher Ni region was about tions were typically developed for the inclusions within a MIM material may Layer thicknesses from AES were 8 wt%. The concentration gradually processing of large metal castings or tend to mitigate grain growth. determined to be 4 nm and 2 nm for decreased from the centre of the Ni large PM products. It should be noted that an increasing the oxygen- and fluorine-rich layers rich area to the matrix region. The population of non-metallic inclusions respectively (Fig. 11). concentration reduced to around 4 The relationship between MIM negatively affects the same properties These various characterisation wt% Ni in the surrounding matrix process variables and HIP that a part maker hopes to improve by techniques were therefore seen to region. Fig. 13 shows the schematic densification eliminating porosity via HIP. produce remarkably self-consistent diagram of a single Ni rich area and The paper, presented by Stephen If a parts maker desires to make results. It was concluded that, if the surrounding matrix region for the Mashl (Michigan Technological a pore-free MIM part having optimal provided with the proper temperature Fe-6Ni-0.4C compact using fine Ni University), Alan Sago (Net Shape mechanical properties it is necessary profiles, a novel multi-layer passivation powder after heat treatment. Technologies) and Robert Conaway (IFI to both minimise and preferably elimi- coating can be created in-situ during Four heterogeneous models atomisation. and one homogeneous model were constructed, as defined in Fig. 14. The Nickel Concentration Region Hetero- full characteristics of these models are Model 8 mass% 6 mass% 4 mass% geneity (%) Structure-property summarised in Table 1. relationships in MIM Fe-Ni The simulated results from the Hetero-100 50 vol% 0 vol% 50 vol% 1 00 alloy steels model were compared with experimentally observed behaviour, and showed Hetero-80 40 vol% 20 vol% 40 vol% 80 Fine heterogeneous microstructure Fig. 14 FEA models used in the study. The models were identified as (a) hetero-100, good agreement, Hetero-60 30 vol% 40 vol% 30 vol% 60 and mechanical properties of MIM (b) hetero-80, (c) hetero-60, (d) hetero-40 and (e) hetero-0 (homogeneous). From Modelling, in fact, has predicted that Fe-Ni alloy steels presentation by W S W Harun et al. at PowderMet 2013 (Courtesy MPIF) the best mechanical properties, of 2272 Hetero-40 20 vol% 60 vol% 20 vol% 40 Wan Sharuzi Wan Harun, Toshiko MPa UTS and 7.7% elongation, could Hetero-0 0 vol% 100 vol% 0 vol% 0 Osada, Yang Xu, Fujio Tsumori and elemental mixes of carbonyl iron and was oil quenched and tempered be attained at a heterogeneity level of (homogeneous) Hideshi Miura (Kyushu University) water atomised Ni, and the resultant following MIM processing. 40% (Fig. 15). reported on a study of the heteroge- mechanical properties. EPMA analysis of the Ni distribu- Table 1 Summary of modelling conditions for Fe-6Ni-0.4C compacts based on the neous microstructure created in MIM The composition Fe-6wt%Ni- tions confirmed that the microstruc- degree of heterogeneity. From presentation by W S W Harun et al at PowderMet 2013 processing of Fe-Ni alloys, based on 0.4wt%C was studied and this material tures of the compacts were consistently (Courtesy MPIF)

The production of micro- and precision PIM parts Examinations on the production of micro and precision PIM parts An important challenge in developing further the capabilities of PIM and MicroPIM is to improve dimensional tolerance control capability. A paper from Volker Piotter, Elvira Honza, Alexander Klein, Tobias Mueller and Klaus Plewa (Karlshuhe Institute of Technology) addressed this issue. Dimensional tolerance control of Fig. 17 Schematic drawing of the test part, Fig. 18 The five positions for +/- 0.2% to +/- 0.5% has been quoted a simple cylinder geometry with a length of diameter measurements Fig. 19 Standard deviations of diameter in the literature, with claims that, 20 mm and a diameter of 2.015 mm in the indicated by arrows. From measurements for both green and sintered in certain cases, +/- 0.1% can be green state. From presentation by V Piotter et presentation by V Piotter et al. at parts. From presentation by V Piotter et al. at achieved. The study reported in this al. at PowderMet 2013 (Courtesy MPIF) PowderMet 2013 (Courtesy MPIF) PowderMet 2013 (Courtesy MPIF) paper set the objective of achieving tolerance control below +/- 0.1%. To aid these accuracy investigations, a new tool was used, which was equipped with two pistons at each end of the cavity. The position and forces Fig. 16 A plot of achieved density as a function of process route. All samples, of the pistons could be controlled regardless of sintered density, HIPed to a nominal 98% density level. From presentation autonomously, thus allowing the gate by S J Mashl et al. at PowderMet 2013 (Courtesy MPIF) position to be varied between die side, middle and ejector side. Label Description As-Sintered Density For these basic trials, a simple cylinder geometry was chosen (Fig. 17). S2 Batch Furnace 1220°C, 1 hour Density = 7.44 – 93.2% The feedstock used was a formula- S3 Pusher Furnace 1290°C,~1 hour Density = 7.59 – 95.0% tion of 67Vol% 17-4PH steel powder (mean diameter approximately 4 μm) S4 Batch Furnace 1350°C, 1 hour Density = 7.65 – 95.8% Fig. 20 A schematic of the IML-MicroPIM process. From presentation by V Piotter Fig. 21 Boundary between tape and PIM and a typical MicroPIM binder system et al. at PowderMet 2013 (Courtesy MPIF) feedstock. From presentation by V Piotter et S5 Batch Furnace 1375°C, 2 hours Density = 7.72 – 96.6% consisting of paraffin wax, PE and al. at PowderMet 2013 (Courtesy MPIF) certain additives. Table 2 Sinter cycle designations. From presentation by S J Mashl et al. at PowderMet Initial trials revealed that the best this can be regarded as an explanation or rolling processes. Before inserting MIM of complex tungsten 2013 (Courtesy MPIF) accuracies could be reached if the for this result. them into the injection moulding devices piston pressure was chosen to be The second part of the paper tool, they can be printed, punched, Label Description Conditions relatively low, i.e. the injected feedstock focussed on the authors’ developments embossed or subjected to other Nuclear fusion is one of the great pushes back the piston in a quasi- hopes of the nuclear power generation H0 no HIP (As-sintered) in combining inmould-labelling and preliminary treatments. In this way, it balanced force state thus avoiding micro powder injection moulding is possible to generate colour patterns community as, unlike nuclear fission, H1 Typical Commercial SS HIP cycle (1120°C / 15 ksi / 4 hour) jetting effects. (IML-MicroPIM). or lateral structures on the surface of it does not give rise to any long-lived Furthermore, an optimised tool Applying the most common means the PIM body. radioactive products. H2 Conservative (long/hot) HIP Cycle (1160°C / 15 ksi / 5 hour) temperature was determined as being of performing multi-component-PIM, Further benefit can be derived from Nuclear fusion involves the collision H3 Rapid High Pressure HIP Cycle (1120°C / 26 ksi / 2 hour) 60°C and a middle gate position was (at least) two feedstocks filled with the opportunity that submicron or even of nuclei of the isotopes of hydrogen, found to be the best position to achieve different powders are injected into a nano-powders can be merged into the deuterium and tritium, causing them H4 Quick HIP like cycle (High pressure, very short dwell) high accuracies. tool more or less simultaneously to foils without the tremendous increase to fuse together to form helium nuclei Having set these parameters, produce a compound green compact. in viscosity that usually arises. and release energy in the form of Table 3 HIP cycle designations. From presentation by S J Mashl et al. at PowderMet diameters of the green and sintered However, this “classical” variant of The process has already been neutrons. 2013 (Courtesy MPIF) cylinders were measured at five 2C-PIM is not the only way to produce investigated for macroscopic applica- The temperatures involved different positions (Fig. 18). multi-component devices. A supple- tions and trials for adaptation to micro in nuclear fusion are very high nate porosity while also minimising result raises the question of whether It transpired that the absolute mentary option is to use a procedure systems technology have been carried (100 million°C). The most promising non-metallic inclusions within the alloy temperature or dwell time could be diameters differed according to the quite similar to the inmould-labelling out within the former EU Large Inte- means of achieving these conditions is of interest. further shortened, potentially providing measuring position. In series precision process, which is well-known in plastic grated Project “Multilayer”. The main “magnetic confinement” of the hot gas, In this work, MIM 316 stainless steel a lower cost route to the high level production, it was considered that this packaging. A pre-fabricated insert in outcome from this project was the as a plasma, in a ring-shaped magnetic tensile specimens, sintered to varying mechanical properties associated with effect might be compensated by an the form of a foil or film is positioned combination of different ZrO2 powder chamber known as a “tokamak”. density levels (Table 2) and HIPed using a pore-free PM material. adequate tool modification. in a tool and, subsequently, covered by fractions in one part. A tight connec- The world’s current largest four significantly different HIP cycles The density data from the “Quick- In relation to the main aim of a backwards injection-moulded layer tion between the former tape and the tokamak, the Joint European Torus (Table 3), yielded similar as-HIPed HIP” like cycle (see Fig. 16), with a high the study, standard deviation of the (Fig. 20). feedstock was obtained (Fig. 21). (JET) at Culham, UK, has produced 16 density level (Fig. 16). pressure and very short dwell, indicate diameter was lowest at the middle Foils filled with metal or ceramic megawatts of fusion power and proved A low temperature HIP cycle yielded that this is quite possible. Follow-up position, i.e. nearest to the gate powders might be manufactured by, its technical feasibility using deuterium similar density levels to a higher mechanical testing will confirm or (Fig. 19). A relatively long time packing for example, slip casting, foil casting, and tritium. temperature, longer time cycle. This refute this suggestion. pressure is effective in this position and

Inovar Communications Ltd method, which inherently combines a shaping and an assembly step, namely POWDER METALLURGY REVIEW 2-Component-WPIM (2C-WPIM), had to be developed. To pursue 2C-WPIM, a new POWDER two-component PIM tool had to be developed to allow the fully automatic METALLURGY replication and joining without brazing of fusion relevant components in one VOL.2 NO.1 VOL.2 SPRING 2013 step and the creation of composite REVIEW materials. Prior assessments had shown that a binary tungsten powder particle system is advantageous with respect to sintering activity and achievable density. For the reported trials, Fig. 22 Various test specimens and divertor components Fig. 23 Comparisons of “thimble-tile” combinations. The first therefore, two types of pure tungsten produced by WPIM. From presentation by V Piotter et al. at sample (left) was produced by one-component PIM and the powders were used, with an average PowderMet 2013 (Courtesy MPIF) second sample (right) by two-component PIM. From presentation grain size distribution of 0.7 μm (W1) by V Piotter et al. at PowderMet 2013 (Courtesy MPIF) or 1.7 μm (W2) Fisher Sub-Sieve Size (FSSS), respectively. Mixing ratio was Material Density Grain size Vickers- setShifting at W1 : W2 = 50%into : 50%. the next gear temperature strength and low erosion composition [% T.D.] [μm] Hardness [HV0.1] The binary tungsten powder particle rate in withstanding the extreme condi- with powder technology systems were doped with 2wt.-% La2O3 W 98.6 - 99.0 5 - 7 457 tions. However, manufacturing of such In recent years Höganäs has proven that transmission gears can be produced through PM technology. In real world testing, machined transmission gears were successfully replaced by PM gears in two demonstrator (W-2La2O3) or with 2wt.-% Y2O3 powder parts by machining processes, such as cars - a Smart car and a rally car. We now continue to push the limits of metal powder technology by adding W-2La O 96.5 - 97.2 >3 586 2 3 (W-2Yhelical2 gearO3 ),compaction respectively. capability to our PoP Centre. This added competence to our industry leading milling and turning, is extremely costly technical centre will enable us to further develop PM gear transmission technologies and conversions for manualTo perform transmissions, dualthe clutch injection systems and electric moulding vehicles. W-2Y2O3 96.3 - 97.1 <3 617 and time consuming because tungsten

trials, the new 2C-tool was used. The Vol 2 No 1 SPRING 2013 is very hard and brittle. A net-shape POWDER METALLURGY IN JAPAN Table 4 Values of density, grain size and hardness of the final densified materials most important feature of this tool was process such as Powder Injection Scan to watch DEVELOPMENTS IN FERROUS PM MATERIALS that it allowed for the production of PM gears in action Moulding is therefore an attractive two divertor components, namely the PROFILE: GKN POWDER METALLURGY The challenge now is to prove fusion by pre-sintering and Hot Isostatic alternative. can work on a power plant scale. Inter- Pressing was developed at KIT. The tungsten tile and the tungsten alloy Typical properties of successfully We push the limits of metal powder. www.hoganas.com/pmc thimble, in one cycle, without additional Published by Inovar Communications Ltd national fusion research is following a new manufacturing sequence had been manufactured divertor parts, consisting ipmd.net assembly steps. roadmap to achieve power generation named Tungsten Powder Injection of pure tungsten alone, were density Metallographic investigations within 30 years. The next stage in this Moulding (WPIM). >98 % T.D., hardness of 457 HV0.1, a showed that the material connection programme is ITER (the International Combinations of pure tungsten grain size of approximately 5 μm and of the 2C-WPIM combinations (W + Tokamak Experimental Reactor), a plus tungsten alloys have been a microstructure without cracks or multinational project that is being built W-2La2O3 and W + W-2Y2O3) could be at Cadarache in the south of France. performed without visible defects: No ITER will be a 500 megawatt tokamak “manufacturing of such parts by cracks or pores could be detected in (equivalent to a small power plant). machining processes, such as milling the seam of the joining zone between Although it will be some decades the W tile and the W-alloy thimble before commercial deployment of and turning, is extremely costly and so a solid and relatively strong bond nuclear fusion could be contemplated, between the two materials can be there is a significant demand in large time consuming because tungsten assumed (Fig. 23). development projects, ITER and A compilation of the measurement possibly beyond, for solutions to the is very hard and brittle. A net-shape results is given in Table 4 and these for the world of many significant material performance suggest that, for both doped material, and engineering challenges that exist. process such as PIM is therefore an the embedded particles act as grain growth inhibitors leading to a smaller PIM of complex tungsten devices attractive alternative” grain size compared to pure PIM A significant challenge, in this context, tungsten. POWDER METALLURGY relates to the so-called “plasma- realised showing almost defect-free porosity. Examples of such parts are facing components”. Tungsten-based boundaries. Examples for fusion shown in Fig. 22. Author materials have emerged as a prime reactor components consisting of pure These fusion energy generation David Whittaker choice for this type of application and tungsten and tungsten alloys (W-La2O3, applications and many others, however, DW Associates the paper by Volker Piotter, Steffen W-Y2O3), including examination of the do not require parts made from tung- 231 Coalway Road Anlusch and Klaus Plewa (Karlsruhe interfaces, were presented in this sten alone. Rather, combinations of Wolverhampton Institute of Technology) reported on paper. W with W-alloys are required in order POWDER WV3 7NG MIM material and process develop- With reference to suitable materials, to reduce the risk of brittle fracture United Kingdom METALLURGY ments aimed at this opportunity. tungsten and tungsten alloys are pres- and to achieve satisfactory joining with Tel/Fax: +44 1902 338498 For this purpose a special process ently considered as the most promising the adjacent sections of the reactor ipmd.net REVIEW Email: [email protected] based on combined compaction candidates primarily due to their high blanket. Therefore, a fabrication

LÖMI’s debinding furnaces can use various organic solvents, including LÖMI: New developments in acetone, ethanol, hexane, heptane and trichloroethylene (TCE). “The solvent debinding furnaces always come solvent and water debinding with a solvent recovery system which provides a fresh debinding medium at all times. The solvent recovery rate of systems for MIM and CIM the system is up to 99%, making our debinding furnaces very economical and environmentally beneficial,” added Marques. The solvent is operated within a closed loop and, together with the debinding furnace being explosion-proof, this ensures a safe work environment. Germany’s LÖMI GmbH is widely recognised as a market leader in The company’s solvent debinding furnaces are available with capacities the production of explosion-proof solvent debinding furnaces for PIM from 50 litres to 2,500 litres. “For and the company has for many years worked in close cooperation small numbers of injection moulded Fig. 2 Three solvent debinding furnaces EBA-900 with a parallel solvent recovery with feedstock and part manufacturers to continuously improve its parts, our EDA series of furnaces system MDA-3000 shortly before commissioning at a major Indian customer combine debinding, vacuum drying technology. As water debinding becomes more important for PIM and solvent recovery in one single producers, the company reports on the latest innovations in its range of unit. For medium and large numbers debinding systems for the industry. of MIM/CIM parts, our systems consist of two units, an EBA series debinding furnace with a capacity of up to 2,500 litres and a parallel solvent recovery system matched to the customer’s process. Should a part producer Located close to Frankfurt, in the In 2001 the company added solvent worldwide, including those that supply later wish to expand its production centre of Germany, LÖMI GmbH was debinding furnaces to its manufacturing the automotive, aerospace and medical capacities, all LÖMI systems can be established in 1991 as a manufacturer portfolio and over a period of just sectors. extended on a modular basis,” stated of solvent recovery systems. From the a few years established itself as a Today the company offers three Marques. start the company has had a strong market leader in this area. Now, with different types of debinding furnaces; research and development focus and over twenty years of experience in one for organic solvent soluble binder many of its systems were developed explosion-proof technology for handling systems, one for water soluble binder Water debinding systems through research initiatives with project flammable solvents, LÖMI offers a systems and one unique furnace type partners such as Fraunhofer-Gesell- range of debinding furnaces for the PIM which is capable of debinding with both Water debinding has to-date primarily schaft and a number of renowned industry. Customers include some of organic solvents and water in one single been used by CIM part producers. German universities. the leading MIM/CIM manufacturers system. LÖMI’s José M Dias Fonseca stated, “In the past some producers used large open water baths to immerse Solvent debinding their green parts. After the debinding systems process, the watery brown parts had Fig. 3 Water debinding furnace Fig. 4 Rental system EDA-50LW for Commenting on the advantages that to be removed from these baths and EBA-50W: a front-end loader with debinding with organic solvents or water the organic solvent debinding process transported and loaded into a drying automatic process and integrated drying in one single furnace for testing new has over other processes, Christian oven. This often caused damage to of parts feedstocks or optimising processes Ferreira Marques, Managing Partner at the brown parts, in addition to the LÖMI, told Powder Injection Moulding increased time span and costs for the International, “The first advantage is extra handling step. We addressed The latest research and and development in recent months, in that MIM/CIM part producers are free in these problems two years ago by development in water close cooperation with some renowned their choice of feedstock, as numerous developing our EBA-W series water debinding MIM/CIM part producers,” continued kinds of feedstock systems can be debinding furnace. These furnaces Dias Fonseca. processed via the solvent debinding are designed as ergonomic front-end “In recent years a number of MIM and “To debind green parts containing process. This makes it easy for part loaders, making it very easy to load CIM part producers have tried to opti- a water soluble binder system, part producers to test new feedstocks, or and unload MIM and CIM parts.” mise their water debinding processes producers often use acidic deminer- to add another feedstock producer as In addition, these systems feature only to find that this technique places alised water. This type of water, along a supplier, without having to invest in the integrated drying of parts so that much higher demands on the perfor- with certain additives and inhibitors a new debinding furnace. In addition, the brown parts can remain within the mance and quality of water debinding which the feedstock producers require solvent debinding furnaces offer a very furnace after the debinding process. equipment than many anticipated. the part producers to add to the long lifetime as the solvent debinding Programmable logic control (PLC) To address these issues and further debinding water, has been shown to process causes very little wear and ensures an automatic process once improve our water debinding furnaces, be capable of corroding even stain- Fig. 1 Solvent debinding furnace EBA-300 with a solvent recovery system MDA-100 tear.” the parts are loaded. we have undertaken extensive research less steel. As a result, this demands

problem was the fact that superfine furnace, LÖMI will customise the purchase of a new debinding furnace,” particles accumulated on the furnace to the producer’s process, stated Wegemann. surfaces of brown parts during the based on the test results,” continued water debinding process. Some- Wegemann. New features and new times smear marks due to additives in the debinding water could be auxiliary equipment found on the brown parts after the Common characteristics Many of the most recent improvements debinding process. We have solved of all LÖMI debinding to the company’s debinding furnaces these problems by developing and solutions and their auxiliary equipment have implementing a specifically modified been directed at making their debinding process,” stated Dias The engineers at LÖMI conduct their operation more ergonomic and Fonseca. research and development in close efficient, thus saving time and costs To facilitate the water debinding cooperation with feedstock producers during the production of PIM parts. process for its customers, LÖMI has and MIM/CIM part manufacturers and Wegemann stated, “As an example embedded sensors into its equip- as a result the company has gained a of some of these improvements, ment that monitor various param- comprehensive understanding of the to facilitate the monitoring of the eters of the utilised water and show entire PIM technology process chain. debinding, drying and solvent recovery them on a display in real time. For This has led to the near continuous processes for the operator, the a higher-quality process (debinding enhancement of the company’s current states of the various process Fig. 5 Mobile loading aids allow easy transportation and preparation of the next batch of and drying), a temperature control debinding furnaces, improving both parameters are now shown on the parts while the current batch is still in the furnace was installed that can reach up to reliability and efficiency. The furnaces display in real time. Additionally, ten target values over a certain time employ well proven technology and we have entirely revised the locking period. This feature is particularly are fully customisable by means mechanism of the front-end sealing important for water debinding of a programmable logic control cover. A ratchet tensioner now enables processes but can also be installed system. Even complex processes can the operator to increase the tightness in solvent debinding furnaces. be operated with a LÖMI debinding of the equipment even during its furnace, as the company develops operation, at the same time preventing Fig. 7 The new large display in control tailor-made systems specific to Solvent and water him from accidentally opening the cabinet shows current states of various customer requirements. cover.” debinding in one system process parameters in real time for LÖMI is an accredited company “Also, the auxiliary equipment debinding, drying and solvent recovery – for testing and according to the EU Water has been considerably improved and diversifying Framework Directive and its furnaces standardised. A large variety of trays meet European directives for and mobile loading aids are now up within the debinding chamber. “In recent years many producers occupational health and safety, as available in order to save time and As they impaired the quality of the who operate conventional manu- well as environmental protection. An costs during the production process. surfaces of the brown parts, the facturing processes for metal or in-house accredited safety engineer While one batch is still inside the company has completely revised the ceramic parts have learned about will give prospective customers advice debinding furnace, the operator can loading mechanism, which now utilises PIM technology. Some of these where needed. prepare the next batch by placing the wear-free rollers. In addition, the producers are still reluctant to The company’s furnaces feature green parts on trays of different LÖMI- components of the loading mechanism enter into PIM production and wish a high-quality stainless steel design standardised sizes and heights, then within the debinding chamber are now to test it first. Likewise, producers and an integrated drying of parts, stacking these trays onto a mobile completely removable. This makes the Fig. 6 Easy single handed and time saving loading and unloading of debinding furnaces that already use PIM technology are which saves production time and loading aid. When the batch inside the cleaning of the debinding chamber using a loading aid with wear-free rollers looking to diversify their processes costs, as no additional handling of debinding furnace has undergone the significantly easier and the operator or test new feedstocks,” stated the brown parts is required between drying process, the operator can move only needs one hand to remove the Ralf Wegemann, LÖMI’s Marketing debinding and drying. LÖMI’s an empty loading aid right in front loading mechanism from a small increased requirements for the with suitable measures.” Director. debinding furnaces are ergonomically of the opened front-end cover of the furnace. materials and components of a water As a result of its research, LÖMI To meet this demand, the designed as front-end loaders with an debinding furnace and slide the racks debinding furnace. This holds true for undertook a complete review of its company has developed a furnace optimal loading and operating height. of trays with the brown parts easily the material of the process chamber, water debinding furnaces and the capable of debinding with both To facilitate the operation of a system, out of the furnace onto the mobile Contact which no longer can be an ordinary company’s engineers are currently organic solvents and water in one remote diagnostics and maintenance loading aid. Prepared racks of trays Diplom-Ingenieur (FH) José M Dias stainless steel, as well as for the implementing solutions to the system, the first of its kind in the are available, as well as a telephone with the new batch can then be slid Fonseca and Diplom-Ingenieur (FH) materials used in the pumps, hoses, challenges identified. In addition, industry. The system, EDA-50LW, service hotline. into the furnace. This unloading and Christian Ferreira Marques, Managing sensors and actuators. All welded with regards to the drying process, it is available as a rental system so “Our furnaces are cost-saving loading procedure now takes only a few Partners seams also needed to be reviewed became evident that vacuum drying that prospective PIM producers through their compact and energy- moments, making switching batches and the welding process modified alone was not sufficient. Water can test their processes in their saving design, their low investment between processes much more LÖMI GmbH where applicable. All the surfaces bubbles could form on the loading own company. “Experienced PIM and a short lead time. Generally, one efficient and cost-saving.” Am Gemeindegraben 10 with direct contact to water vapour trays and these made the green parts producers can try out new kinds of of our furnaces pays for itself within Until a few months ago, the loading 63741 Aschaffenburg have to be reappraised and, where move, sometimes even making them feedstock and/or binder systems or one or two years after commissioning. mechanism used stationary mounted Germany needed, their materials replaced. In stick together. As a solution, the optimise their existing processes, Rental systems are also available for metal rails within the debinding Tel: +49 6021 447799 0 addition, when water is used to debind company has developed and installed using both organic solvents and prospective customers to test their chamber, and the metal racks with the Fax: +49 6021 447799 30 metal parts from a MIM process, this a specific new drying technology. water to debind their green parts. debinding processes in-house in their green parts were slid onto these rails. Email: [email protected] often leads to corrosion of the parts “For manufacturers of medical Should a PIM parts producer later own companies. The costs for the This used to cause abrasive wear and www.loemi.com themselves. This has to be prevented devices and luxury goods, a major decide to puchase a new debinding rental system can be credited to a small metal particles therefore ended

Global PIM Patents The development of an innovative continuous belt furnace for the high temperature sintering of MIM and The following abstracts of PIM-related patents have been derived from the European Patent Organisation databases of patents from CIM products throughout the world. Scott K Robinson

Centorr Vacuum Industries, Inc., 55 Northeastern Blvd., Nashua NH 03062, USA Email: [email protected]

point of the organic binders, adding the Centorr Vacuum Industries, based in Nashua, New Hampshire, USA, has specialised in the development, WO2011018087 (A1) organic binders in melted form, making engineering, design and manufacture of vacuum and controlled atmosphere furnaces since 1954. In MANUFACTURING METHOD OF A sure that the temperature does not fall the following paper the company introduces a unique low mass, fast throughput belt furnace design VALVE below the melting point of the organic that operates in ultra clean environments of inert or process hydrogen gas that can be used over a wide Publication date: 2011-02-17 binders; forming the parts by powder temperature range from 1000°C up to 2800°C. While this continuous furnace design is not suitable for all Inventor(s): Hoeyer Jesper Hoejland injection moulding or extrusion; applications, if considered for the right process, it can provide the combined benefits of fast cycle times in an et al., Danfoss AS, Denmark removing the organic binders from the oxygen free atmosphere. A method of manufacturing a valve obtained parts by a debinding step; and using Metal Injection Moulding is sintering the parts. disclosed in this patent. The valve housing comprises a welding cap for

welding the upper part of the valve to the valve housing. The welding WO2011120066 (A1) cap is placed so the upper part can METHOD FOR PRODUCING SHAPED be welded to the housing without BODIES FROM ALUMINIUM ALLOYS damaging the inner cavity of the the heat from the welding does not Publication date: 2011-10-06 housing. There is a gap between the damage the inner liner, allowing the Inventor(s): Danninger Herbert et al., Processing metals and ceramics can require very special sintering are typically shut down only one to two times over several years of welding cap and the inner liner so inner parts of the valve to move freely. Univ Wien Tec, Austria conditions and operating environments in order to achieve optimal use, and not every application can justify these production capacity The invention relates to a method for physical properties. While conventional vacuum, atmosphere requirements. They must also be cycled with dummy loads during CN101643355 (A) for the first time and explores suitable producing shaped bodies based on batch, and continuous belt or pusher furnace designs work well for periods of non use to prevent overheating of the main chamber. INJECTION MOULDING TECHNIQUE grain boundary doping components aluminium alloys by metal powder a majority of these applications, there are some unique materials For improved cleanliness, some designs also include a “humpback” FOR TRANSLUCENT ALUMINA evenly spread in alumina ceramics so injection moulding. The process (or processes) that could benefit from an ultra clean, oxygen free feature which lifts the belt and load into a higher area of the hot CERAMIC BULBS as to prepare the high-performance comprises the following steps: a) environment and a fast ramping speed with minimal soaking times. zone where cleaner, lower dewpoint hydrogen gas is present. Publication date: 2010-02-10 translucent alumina ceramics for metal preparing a feedstock by blending the Although vacuum and atmosphere batch furnaces are commonly To address the above concerns and accommodate these niche Inventor(s): Xueguo Zhao et al, halide lamps. metals contained in the desired alloy used in industry, cycle times can be long and there can be variances small volume and fast throughput applications a new style of Changsha Jingtai Plastic Machinery in the form of metal powders and/or present throughout the load, especially when processing a large furnace design was conceived which was born of the benefits Technology Development Co., Ltd, one or more metal alloy powders with quantity of small parts in a large furnace chamber. This is especially of vacuum batch furnaces, with the processing speed and China a binder; b) preparing a green compact the case where fixturing and setter furniture like hearth plates can process uniformity found in continuous designs. This novel high The invention discloses an injection WO2011149401 (A1) by injection moulding the feedstock; cause thermal scattering of the heat or act as a heat sink for the temperature continuous belt furnace is shown in Fig. 2. moulding technique for translucent METHOD FOR PRODUCING CEMENTED c) preparing a brown compact by at small components. alumina ceramic bulbs. The process for CARBIDE PRODUCTS least partially removing the binder from Conventional belt furnaces utilise Inconel mesh belts, have integral ceramic bulbs comprises the Publication date: 2011-12-01 the green compact by catalytic and/ refractory ceramic (brick or fibre) insulation, and can process following steps: proportioning, mixing Inventor(s): Jonsson Per et al., Seco or solvent and/or thermal debinding; loads of many kilogrammes per m2 of belt area. They are typically materials, granulating, pressing a Tools AB, Sweden d) sintering the at least partially de- rated for maximum continuous use at temperatures to 1150°C or fusible core, inserting the fusible core, The patent relates to a method for bindered brown compact to obtain the up to 1288°C for units with ceramic belts. While large belt and injection moulding, debinding, biscuit the production of cemented carbide desired shaped body. The invention pusher furnaces are ideally suited for high throughput applications firing, co-firing and high-temperature based hard metal parts comprising is characterised in that in step c) the such as those found in the Powder Metallurgy industry, they are sintering. hard constituents in a binder phase by binder is removed completely, wherein, not as economical for lower volume, shorter furnace runs of small The injection moulding technique using Powder Injection Moulding or optionally after carrying out one or parts under 6-12 mm in size that need to be run in ultra clean for split-type ceramic bulbs comprises extrusion. The method comprises of: more preceding de-binding stages, a environments. These conventional belt furnaces require expensive the following steps: proportioning, mixing powders of hard constituents thermal debinding in order to remove nickel alloy or ceramic muffles inside the hot zone to help control, mixing materials, granulating, injection and binder phase to form a mixture; the (residual) binder is effected and protect and direct the reducing gas away from the insulation and moulding, degreasing, biscuit firing, co- heating said mixture of hard is carried out in an atmosphere heating elements, and maintain the desired furnace atmosphere. firing and high-temperature sintering. constituents and binder phase to a containing at least 0.5% by volume These muffles can have a short lifespan if cycled frequently and The technique utilises the injection temperature; when the temperature of oxygen, after which the resulting for this reason, once the units are heated up, they are seldom moulding process for preparing of the mixture of hard constituents completely de-bindered brown compact turned off and instead idled over weekends or periods of low translucent alumina ceramic bulbs and binder phase is above the melting is sintered. production rather than turned off completely. Large belt furnaces Fig. 1 Conventional vacuum furnace hot zone

While this unique belt furnace design was originally introduced in the early 1990s its popularity has recently begun to rise in the past five years as a number of new applications have opened up for its use. The furnace is built similar to vacuum furnace construction with a water cooled stainless steel chamber and an interior hot zone designed using refractory metals for the heating elements and shielding (such as molybdenum or tungsten), or rigid graphite insulation and graphite elements for ceramics applications. These unique continuous furnaces are rated for maximum temperatures of 2000°C in either inert or process hydrogen gas with a refractory metal hot zone, or up to 2800°C in inert gas when using graphite hot zones. To provide fast heat up and cool downs, double wall water jacketed entrance and cooling tunnels are located on the ends of the chamber. For material transport, the furnace is fitted with a range of belt materials depending on use temperature and Fig. 4 Proximity sensors at the exit tunnels signal to operators when a Fig. 6 Centorr Vacuum Industries belt furnace for the processing of load weights. This includes a proprietary patented molybdenum or work tray is ready for unloading advanced metals and ceramics tungsten mesh belt design rated to 1550°C or 2000°C. For higher load applications, silicon carbide link belts are used to 1800°C, Fig. 2 2000°C rated belt furnace for sintering refractory metals in and for temperatures over 2200°C flexible graphite cloth is the belt hydrogen gas material of choice. The furnaces are available in a range of sizes and throughputs, with a nominal belt width of between 50 - 200 mm, a height of 25 - 100 mm, and a length dependent on the desired throughput, but typically 200 - 1525 mm. They are configured in either one, two, three, four or five zones of control and achieve excellent temperature uniformities of +/- 3 to 5°C across the belt in inert or hydrogen process gas. The throughput and process repeatability have made this furnace a successful tool for dependable production in applications such as Metal Injection Moulding, the high temperatures sintering of refractory metals and ceramics, precision brazing, metallization and the ceramic to metal joining of components. Recent installations to date have centred around applications in Micro-MIM parts, silicon nitride components, high temperature sintering and hydrogen brazing. Four application case histories are presented below. Fig. 7 Trays of small hinges on varied ceramic setter materials Fig. 8 Photograph of stainless steel component including sapphire, ceramic paper and alumina powder Metal Injection Moulding A MIM parts producer was looking to manufacture large quantities of a relatively small part with the flexibility to start and stop runs several times per week. These parts were made of stainless grades including 17-4PH or 316L and applications included orthodontic braces and brackets, cell phone cam hinge pieces and miscellaneous Fig. 3 Refractory metal belt furnace hot zones small parts weighing under 5 g each. Unlike the previous applications, this one added the complexity of removing up to 1-3 wt% of a difficult polymer based binder system commonly used in Metal Injection Moulded parts during a low temperature binder burnout step. In this case the belt furnace’s hydrogen flowthrough gas provided an excellent vehicle to breakdown the binder’s hydrocarbon chains so that offgassing could be safely removed from the parts, and reduced to gaseous form with little solid binder residue left in the entrance tunnel. In certain applications a gas moisturising system can be added for processes requiring higher hydrogen gas dewpoints (typically from -20°C to over + 20°C), such as used in metallising applications, or Fig. 9 Microstructure of part with 97% theoretical density Fig. 10 Belt furnace time/temperature modelling curve for a MIM process run at 25 instances where moisture assists in the binder removal phase. mm/min, yielding fully sintered parts in 120 minute cycle time The small cross section and fast throughput of the belt furnace was advantageous in providing a thorough and uniform debinding environment inside the furnace even at the tunnel ends, and ensure also evaluated to minimise sticking of the parts to the metal trays. environment which is considered a bottleneck in batch sintering that the hydrogen process gas is directed up the burnoff chimneys Future work in the MIM field is being performed to determine applications where larger loads must be debound slowly with located at both ends. the effect of cycle times on carbon control and investigating blended several holds at intermittent temperatures. By keeping the load Final sintering of the parts takes place in the main furnace gas atmospheres in an effort to reduce operating costs. Future weights light and the furnace cross section small the parts are chamber and the three zones of control are individually adjusted development work will additionally include adding debinding intimately and quickly debound before entering the sintering to get the desired heatup, soak time, and cool down profile, which capabilities in order to provide a two stage debind and sinter design section. By using a specially designed gas labrynth curtain at the results in theoretical densities of 97% for the 316L components in for MIM parts. Fig. 4 Refractory metal belt furnace hot zones entrance and exit zones, the customer is able to maintain the clean cycle times of 120 minutes. Various trays and setting material were

the SiO vapour attack that dissociated off the load was degrading to small independent manufacturing cells where a pick and place robot involving active metal or Ti-Cu-Ag/Ti-Cu-Ni formulations. the refractory metal. Later designs at SIU used an all graphite hot automatically loads the parts onto small trays that are continuously A customer had a difficult brazing request for a small medical zone with rigid graphite board insulation and graphite resistance queued up in front of the belt furnace entrance. Proximity switch part that used a tiny amount of braze at temperatures under heating elements. sensors located at the exit of the belt furnace signal when a boat is 1100°C. After testing in various vacuum batch furnaces and batch And while SiC formation was a concern with the graphite hot ready for unloading, and can be interlocked to put the belt furnace hydrogen units it was decided to try the parts in the belt furnace zone, the new belt furnace hot zone lasts significantly longer than drive motor into hold, if a tray is not removed from the unloading using hydrogen process gas to maintain a clean, oxygen free what is achieved in graphite batch furnaces or tungsten refractory area. environment. While the parts processed in the batch cycles were metal designs. Fears about a graphite hot zone contributing to a Because the small belt furnaces can be heated up to temperature acceptable, there were braze blush variances throughout the load carbon reaction layer have also been alleviated as there was no from a cold start and operational in under 90 minutes, the belt due to the different thermal conditions each part was subjected to, difference in the material properties produced in tungsten versus furnaces are run either weekly (Monday through Friday), or can and each cycle took on the order of three to four hours, whether the Graphite hot zones. be run daily similar to a batch furnace and cycled on an 8:00 am to unit had a full load or not. In recent years, this work has transferred over to other ceramic 5:00 pm schedule depending on production volumes and holiday After completing two days of test runs at varying belt speeds formulations traditionally processed in batch sintering furnaces and schedules. There is no longer the requirement to run the units at and zone temperatures, the customer achieved parts that exited has led to more work in oxide sintering with sapphire formulations lower idling temperatures over the weekend if production demands the 15.25 cm wide by 91.5 cm long hydrogen belt with excellent Fig. 11 Graphite hot zone and SiC belt in ceramic belt furnace for applications in wafer annealing and LED processing, and don’t require the throughput, which allows for significant savings surface finish, a bright shiny exterior, and excellent braze joints. polycrystalline alumina for metal halide lighting. Benefits of in energy costs, as well as process and inert gas costs. At the end Furnace speeds of 75 mm/min were used during development, Ceramic processing improved densification, minimised weight loss due to dissociation, of each process campaign the belt furnace is powered down and which provided a door to door time of just under 40 minutes. For and preferred crystallinity are possible with this unique belt furnace purged with inert gas for approximately 30 - 60 minutes before budget reasons and total capacity requirements, this customer In 1993, Centorr Vacuum Industries cooperated in a study by Prof. design. it reaches room temperature. Compare this to conventional brick opted for a 10 cm wide belt furnace with an 20 cm long hot zone. Dale Wittmer, Southern Illinois University (SIU), USA, to develop lined units that take two to five days to cool down depending on While a belt speed of approximately 13 mm/min would have been a cost effective means of sintering selected Si3N4 compositions in High temperature sintering maximum operating temperatures, and the operating cost savings appropriate to provide a similar time at temp inside the furnace hot large volumes required by the automotive industry. While these at this customer were further multiplied. Another benefit is that zone, compared with the lab testing in the 91.5 cm long unit, this parts could be reliably produced in a batch process, the major When faced with high temperatures and low dewpoint hydrogen problems such as tunnel blockages, stuck trays, or minor hot zone customer made their initial runs at the same 75 mm/min speeds and barrier to extensive use of Si3N4 components was cost. The primary gas requirements for the sintering of refractory metal components or belt repairs can be readily accessed and corrected in under a day found that the parts came out every bit as shiny and clean as the areas of research had to do with evaluating low cost raw material used in consumer electronic applications, a customer had a choice including time for cool down and reheating due to the novel hot lab testing done in the longer belt furnace design. While not true powders and the sintering process. Previously, Wittmer and Miller of using either high temperature ceramic lined pusher furnaces, zone design. The overall length foot print of this customer’s small for all applications, because the mass of these parts were so small showed that it was feasible to sinter large Si3N4 disks of 100 - 150 or expensive refractory metal batch furnaces. However, because belt furnace fits in a 2.8 m long space, which was less than half the this customer found that their parts would almost instantaneously g to full density in a continuous belt furnace in flowing nitrogen the customer’s parts were small and the volumes were not large length of a conventional brick lined continuous furnace. heat up inside the hot zone, being bathed by the low dewpoint H2 gas. A comparison was made between continuous sintering in in terms of mass, large pusher or batch furnaces were not an It is important to note that these high temperature continuous gas, and due to the small amount of braze material present, result in a commercial belt furnace and sintering in a batch furnace for economical solution. furnaces are generally limited to applications with light part contamination free joining in a matter of seconds. This application similar times and temperatures [1]. For the Si3N4 sintered in the Due to the fact that refractory metals are very sensitive to oxygen weights up to 1.3 kg/linear 300 mm of belt length for molybdenum in a way simulated the speeds of batch induction brazing, except for belt furnace, the average four point flexural strength was found contamination, which is very damaging at high temperatures, the and tungsten mesh belts, and up to 4 kg/linear 300 mm of belt the ability to continuously and safely maintain the clean hydrogen to be 35% higher with a fracture toughness over 22% greater. cleanliness of the furnace interior is of paramount importance. width for SiC link belts, so thought needs to go into the choice gas environment. Remarkably, the overall cycle times for the continuous process The small belt furnace design utilises refractory metal insulation of fixturing for these furnace designs. Operators should consider The only operational issues onsite have been related to were in the range of 3.5 - 4.5 hours compared with 18 - 24 hours shielding and heating elements which generate no significant the use of low mass plates or trays, made of thin molybdenum or environmental conditions on the shop floor. Due to the small size cycles in batch sintering furnaces, and this translated to a reduction offgassing inside the furnace as can be found with traditional tungsten sheet material, with lightweight ceramic separator plates of the furnace openings, if the entrance or exit tunnels are close in time at sintering temperature of 30-60 minutes for continuous porous refractory brick or fibre insulation materials. In fact no if required by the process. Dense ceramic plates cannot be used in to a loading dock or large window, the gas curtains and process compared with more than three hours in the batch process. It was ‘conditioning’ (running the furnace for one to three days upon most instances, as the fast cooling that occurs in the cooling tunnel gas chimneys can have their flow patterns disturbed resulting in determined that this reduced time in the presence of flowing nitrogen initial startup to drive off moisture from the insulation brickwork), results in thermal shock and cracking of the ceramics. frequent flow adjustments to the gas panel. It was also learned that gas, was one of the main reasons the continuous furnace provided is necessary with this belt furnace design, and it is simply purged the furnace preferred to be run with a full load of workboats to enhanced material physical properties. Another explanation why with inert gas for 30 - 45 minutes at the start of the cycle to ensure Brazing get consistent gas flow dynamics, or else the process gas that is the continuous furnace made parts with improved properties when an oxygen content of under 10 ppm, as interlocked by an integrally introduced into the main chamber and entrance/exit tunnels will compared with pressureless sintered furnaces, or even overpressure mounted oxygen monitor. These belt furnace designs routinely Conventional brazing encompasses a wide variety of techniques preferentially exit out the furnace end with the smallest blockage. furnaces is that the belt furnace provides very fast uniform heating achieve the same dewpoint of hydrogen gas inside the hot zone and materials, and can be performed in a variety of furnace Happily, the customer has noticed that the water cooled shell of the and cooling (as the effective hot zone is essentially a 100 mm x 100 during operation as is measured at the gas bottle inlet (typically in equipment; however, for some specialised braze materials either furnace results in almost no heat radiation to the surrounding plant mm square), which positively affects the structure of the material. the range of -50 to -60°C). vacuum batch processing or hydrogen belt or pusher furnaces are environment (as opposed to the significant heat generated from Depending on formulation, the parts could be processed in The customer in question ended up with multiple belt furnaces used. One such niche process would be for the precision brazing conventional brick lined furnaces), and the furnace operation has graphite, BN, or ALN workboxes with or without the use of with 5 cm and 10 cm wide tungsten mesh belt and 20 - 30 cm long of very small, lightweight parts such as those found in the medical not impacted facility heating or air conditioning utilities packing powders. Early work was done in a tungsten hot zone but hot zones rated for operation at 2000°C. The units are set up in industry. The secret to excellent brazing in this case is summarised by the mantra of “get to temperature quickly, stay there a short References period of time, and get down in temperature quickly”. The primary EFFECTIVE HOT ZONE OVERTEMPERATURE [1] D. E. Wittmer, J. J. Conover, V. A. Knapp, Southern Illinois THERMOCOUPLES reason for this sentiment is the desire to minimise high temperature University, Carbondale, IL; C. W. Miller Jr., Centorr Vacuum Industries, (3) PLCS reactions between the braze filler metal and base metal which can Inc. Economic Comparison of Continuous and Batch Sintering of occur if the two materials are in contact at temperatures above the Silicon Nitride liquidus point for long periods of time. A second corollary reason [2] D. E. Wittmer and G. Goransson, Southern Illinois University, is that the shorter the overall cycle time, the less time there is Carbondale, IL; Tn. Tiegs and J. Schroeder, Oak Ridge National available for contamination of the base metal to occur which can Laboratory, Oak Ridge, TN, Comparison of Batch and Continuous result in brazing defects such as poor adhesion between base metal Sintering of Aluminide bonded Titanium Carbide and filler metal, and insufficient bonding properties. [3] D. E. Wittmer, S. P. Etherton, P.M Holgesson, Southern Illinois University, Carbondale, IL, M. McGown, and J. Kellogg – Centorr BELT DIRECTION In order to achieve this goal a very clean “vacuum like” atmosphere Vacuum Industires, Inc. – The Influence of Continuous Sintering on the is desired to ensure little to no oxidation of the base metal. This means Properties of Si3N4 ACCESSORY PORTS (PLUGGED) (4) PLCS conventional belt or pusher furnaces could not be used because these [4] J. L. Johnson Ph.D. AMTellect, Inc, S. K. Robinson Centorr Vacuum designs cannot offer the fast cycle times and level of cleanliness Industries, Inc., Debinding and Sintering of Micro-MIM Components Fig. 12 Hot Zone layout of three zone Ceramic belt furnace and low dew point required for some braze processes, such as those in Continuous Belt Furnace with Rapid Cycle Time Compression

These drawbacks can include difficulties in the control of Furnace design challenges New two-unit one step batch debinding carbon levels, especially in low carbon stainless steels or other PIM parts are made of different metal powders ranging from iron alloys which have high affinity to carbon pick up, resulting in the - nickel to stainless steel, and from titanium alloys to superalloys. deterioration of mechanical properties of final products. Each of these materials may require the use of different types of and clean sintering system for In a technical development designed to address these challenges binders, which are often removed by catalytic debinding process Elino Industrie-Ofenbau GmbH developed the MIM-ECO CT one from the products under atmospheric pressure or partial pressure. improved efficiency and carbon control step complete debinding furnace (Fig. 1) along with MIM-ECO VR The atmosphere of this process is nitrogen as well as chemical sintering furnace. The one step debinding unit includes catalytic acid additives, such as HNO3 at a concentration of 98-100%. debinding, thermal debinding and pre-sintering up to 950°C and In the debinding furnace the heating elements are outside a in the MIM process is designed with a convection system to allow for temperature hermetically sealed hot zone, whilst in the sintering furnace the homogeneity of less than ±5°C. The special off gas burner system heating elements are inside a hermetically sealed hot zone. Both is installed to convert process gases into environmental acceptable types of devices are characterised by different properties from exhaust gases. the point of view of physics and thermodynamics of the process. Gregory Matula, Ijaz Mohsin Different atmospheres (Ar, H2, N2, air, N2-H2) can be used The first difference is the temperature distribution in the hot during the thermal debinding process depending on selection of the zone. A device with a cold wall can reach ± 10K of temperature Elino Industrie-Ofenbau GmbH, Düren, Germany materials, including under air for Ceramic Injection Moulded (CIM) distribution while for comparison a furnace with the hot wall Email: [email protected] products. Users can switch to different protective atmospheres can reach ± 5K. For the selection of these individual designs, during the process prior to the pre-sintering step to enable good previous experience had been taken into account that showed the Elino Industrie-Ofenbau GmbH, Düren, Germany, has developed a new batch furnace system specifically for metal-metal bonding. need for high temperature accuracy during the debinding process the Powder Injection Moulding (PIM) process. Consisting of two units, the first unit has been developed for Water/solvent debound parts can be dried between 80-90°C and combined with a sufficiently high flow of process gas. For the the complete debinding of MIM parts, from initial catalytic debinding to thermal residual debinding and pre- individual temperature-time profiles can be defined for different sintering phase under atmosphere the temperature homogeneity sintering up to 950°C, with changeable atmosphere during the process. The second unit is designed for very debinding steps with different atmosphere. Production can be is even better than ± 10K but for sintering processes under clean sintering that is free from carbon contamination and can be operated under different process gases increased up to three cycles in a day with the air cooling system. vacuum it showed that at the applied high temperatures the and vacuum up to maximum sintering temperature of 1450°C on the standard system, or 1600°C on an In the thermal debinding step the complete removal of residual radiation in between the parts assures more than sufficient upgraded system. The main advantages of the new system are fast production, the avoidance of carbon pick binder is beneficial, so when transferring the parts into the sintering homogeneity. up especially in Mo, W, and Fe alloys, longer life time of hot zone and heating elements, and improved cost furnace they free from hydrocarbons. Another important element for debinding and sintering is the efficiency. This two furnace system has been tested with 316 L and 17-4 PH materials and the technology The speed of the sintering cycle in the MIM-ECO VR can be thermodynamic potential of a chemical reaction. This depends on was able to deliver sintered densities of 7.70 g/cm3 and 7.65 g/cm3 respectively without any distortion in the increased by using a fast heating ramp and can increase production the characteristics of the process as well as on the use of a device MIM parts. up to three complete cycles in a day (24 hours). Some key results of with a cold or hot wall. This consequently leads to the requirement the new sintering furnace are; no condensation, no contamination, of a proper gas flow which is necessary for the processes under no blockages in the vacuum pump and long lasting life time of consideration. the muffle, which is completely made of molybdenum. The charge The thermodynamic potential drop is a measure of chemical carrier fits exactly the same way in sintering furnace as inthe affinity of reacting bodies, which shows the tendency of debinding furnace, so handling of the charge carrier will be easier. substrate to combine into a particular chemical compound. The The main benefit of splitting debinding and sintering operations thermodynamic potential can be compared to the potential energy is the avoidance of carbon pick up during sintering, particularly of the mechanical system. Therefore, while the reaction takes in case of Fe, W and Mo alloys. Materials that are reactive with place, the ΔG must have a negative value and be less than the The Metal Injection Moulding (MIM) process is an efficient or a catalytic method in one furnace and then the backbone binder atmosphere such as Ta and Ti alloy can be sintered with fewer equilibrium state. The chemical reaction proceeds more easily as -2 -5 method for the high volume production of complex shaped is removed thermally followed by a sintering process in another impurities under vacuum level from 10 to 10 and with a the negative value of ΔG increases. This is general approach for components from powders for high performance applications. The separate furnace. In these cases secondary thermal debinding and temperature accuracy of less than ±10K at sintering temperature. catalytic , thermal and sintering processes. MIM process consists of mixing a small amount of organic material sintering process are done in the same furnace, resulting in some with the desired inorganic powder (metals or alloys) to create a drawbacks. feedstock that can flow like plastic under temperature and pressure. Following standard polymer processing techniques, this feedstock can be injection moulded into a ‘green’ shape that is an oversized replica of the final part. Generally, the organic binder is removed during a step known as debinding, usually carried out in at least two stages. After debinding, the part is consolidated to high densities by sintering at appropriate temperature. In this way the MIM process provides designers and engineers with a powerful material shaping technique that can form metals and alloys into extremely complex shapes. Usually the major binder component is removed in a first stage debinding process, for example through solvent extraction or by catalytic decomposition, resulting in the ‘brown’ part. This brown part still contains binder, but only a small amount of organic phase binder, the so called backbone component that grants the stability of the brown part necessary for handling. Thermal debinding is then the most common method for the final removal of this residual polymer from a MIM compact prior to sintering. Current batch furnace technology does not provide a one step complete MIM debinding system. Usually current processing systems remove the first part of the binder by solvent extraction Fig. 1 Furnace TYPE CT MIM-ECO Fig. 2 The technological process parameters of complete debinding and sintering of a MIM part

CT CT CT CT CT VR VR VR VR VR Type MIM Eco Type MIM Eco 025- 050- 100- 150- 300- 025- 050- 100- 150- 300- Unit Unit 095 095 095 095 095 145 145 145 145 145 Effective volume Effective volume 25 50 100 150 300 25 50 100 150 300 (approx. litres) (approx. litres) Loading width Loading width 280 280 420 420 560 280 280 420 420 560 (mm) (mm) Loading height Loading height 300 300 400 400 500 300 300 400 400 500 (mm) (mm) Loading depth Loading depth 310 620 620 930 1240 310 620 620 930 1240 (mm) (mm) Max. batch Max. batch 30 60 120 180 360 30 60 120 180 360 weight (kg) weight (kg) Max. Max. temp. in 1450 1450 1450 1450 1450 950 temperature (°C) °C (option) (1600) (1600) (1600) (1600) (1600) Installed load at Installed load at 30 60 90 120 210 165 165 195 250 400 3 x 400 V (kW) 3 x 400 V (kW) Nitrogen Nitrogen 5 10 10 12 15 2 3 4 4 4 (Nm³/h) (Nm³/h) Hydrogen Hydrogen 2 5 10 12 15 2 3 4 4 4 (Nm³/h) (Nm³/h)

Table 1 The standard unit sizes for one step debinding process Table 2 The standard specifications of ECO-MIM devices for sintering process

appropriate orientation of process gas circulation controlled by a average, the standard device reaches a heating rate of 15 K/min and fan located in the rear of the device. Due to the acids and high cooling rate to 5 K/min. The system control allows adopting these temperatures, plus hydrogen, the electric motor and its connection values dependent on the technological process. The entire structure Fig. 3 Batch debinding ECO -MIM unit CT050-085 to the rotor feature a specially constructed solution to thoroughly is CE-marked and meets the ATEX requirements. ensure basic heat treatment parameters while ensuring safety Typical processes of catalytic, thermal debinding and sintering 950°C forced the engineers to find the most sophisticated sealing at work. A very important factor in this part of the unit is the may be carried out in gas pressures from atmospheric 1010 mbar solutions. This is critical as it is no longer only the process itself configuration of steel materials, which allows for long-term work Sintering unit ECO-MIM-VR to a vacuum of 0.10 mbar. In exceptional cases the vacuum can be that needs to be considered, but also the safety of workers. It is in a harmful environment. This is the result of many hours of The sintering furnace is also supplied in five basic sizes. Table 2 -5 much lower, around 10 mbar. best to use polytetrafluoroethylene -[-CF2-CF2-]n for the acids, but calculations and optimisation with the use of the software for CFD shows the basic specifications of the device. It is a typical cold wall Regardless of the chemical reaction of gases and acids, at high it cannot be used in flanged joints exposed to temperatures higher and FEM calculations. system with heating elements placed inside a metal muffle - the hot temperature a phenomenon of selective sublimation takes place in than 200ºC. However these are exactly the joints used in devices Protection is also achieved by a three-stage gas curtain. This zone (Fig. 4). components of the processed materials or a binder. Importantly, for catalytic debinding, for example for supplying acid into the prevents both the corrosion by the acid and the contamination of The muffle itself is made of molybdenum screens or, foran the vapour pressure over a specific material at a given temperature interior of the hot zone. What can be used here are inert gases the cooler parts of the device with binder. The gas flow from these application of higher temperatures, a combination of molybdenum can be determined by considering the balance between the number and gas curtains determined with CFD methods. But one should curtains is fully synchronised with the process parameters. and tungsten screens. The metal muffle is placed in a vacuum-tight of evaporating and condensing particles. It is necessary to have keep in mind that the type and volume of the flowing gas has an In addition to the gas system controlled by the MFC valves, a housing with a double-wall. The double-wall designs provides the knowledge of pressures and temperatures of sublimation in impact on the final result of the machined work piece as well as system of complete combustion of process pollutants is located on for the space between the inner and outer jacket in which water the selection of construction materials of the furnace and in the on building-up of binder on the colder parts of the device. This the outside of the device. This system operates with a fan which is is circulating to cool the entire device. The process gases supplied selection of the vacuum for a given technology. eventually causes downtime and the need for service. In Fig. 2 the also used for the cooling of the device during the final phase. On through special collectors are fully monitored by a set of sensors A major challenge is therefore to prevent this phenomenon, complete debinding and sintering process can be seen for 316 LA which in the devices with a cold wall undoubtedly has an adverse and 16-4 PH MIM parts indicating the use of the MIMECO CT and influence both on the properties of the thermal insulation, the MIM-ECO VR models. The sintered densities were measured by electrical connections of the heating elements, the heating elements the Archimedes method and obtained excellent results. themselves and especially on the operation of the vacuum pumps. In practice we are dealing with turbulent, laminar and molecular gas flows. One-step debind and pre-sinter unit ECO-MIM-CT It should be noted, however, that a very important element for The debinding unit ECO-MIM-CT is supplied in five sizes. These the proper debinding process is a laminar flow and for sintering a values are chosen on the basis of many years of practice and in molecular flow of the gases used. The proper way to prepare the accordance with market standards and customer requirements. furnace in order to achieve these flows undoubtedly depends on the Table 1 shows the basic specifications of the device. engineering practice and a thorough understanding of aspects of the The unit is a typical hot wall unit with the heating elements technological processes. located outside the gas-tight and acid-tight metal muffle. Inside the Another challenge, though not the last one, to be faced by an muffle are all necessary connections for supplying and for draining engineer is the atmosphere for the catalytic, the thermal debinding process gases, for supplying acid as well as for the connection of processes and the sintering process, as well as ensuring the accuracy atmosphere sensors and the necessary support elements to place the of the individual processes. work pieces inside. The muffle is a floating design, which means

Catalytic debinding requires the use of acids (HNO3) at a that it has the property of thermal expansion in the horizontal concentration of 98-100% and a temperature of up to 150ºC. direction. Working with an acid and hydrogen at high temperatures up to In addition, the design of the metal muffle allows for the Fig. 4 Batch sintering ECO -MIM furnace type VR 050-145

MIM industry expansion: What does it mean for vacuum furnace technology?

Jerald Balinnang1, Aymeric Goldsteinas2

Ipsen Inc., Cherry Valley, IL 61016, USA 1Product Manager, TITAN DS & TITAN T, email: [email protected] 2Product Development Manager, email: [email protected] Fig. 5 A Continuous MIM furnace developed by Elino

and also the flow is controlled by MFC valves. The device has a sintering furnace can be designed in form of a L-, Z- or U-shape vacuum pump installed in order to obtain vacuum of approximately configuration, giving highest flexibility to fit in restricted production 10-2 mbar. All components in contact with explosive gases have areas. Due to the strict atmosphere separation and the therewith ATEX certifications. The device has a fully safe hydrogen linked atmosphere control schematic, the gas consumption shows With the MIM industry on the rise and expanding across an increasing number of sectors, requirements combustion system, which is designed to prevent misuse by an to be less than 5 m³/h with excellent temperature homogeneity. have been set to ensure that the quality of MIM parts is consistently high and MIM processing operator. The pusher system is designed such that no vibration during the equipment is accurate and efficient. Debinding and sintering furnace performance needs to advance movement of the plates occurs and has shown to be able to transport concurrently in order to accommodate these requirements without sacrificing cost-effective operation. Ipsen Inc. outlines how it has incorporated new technologies to address MIM part quality and Conclusions multi-layer stacks with very small parts without any damage to the parts. economical operation concerns. This paper specifically illustrates how its furnaces’ temperature A brief analysis preceded by many months of engineering research The continuous furnaces have a proven record of achieving uniformity, hot zone design, process gas management and binder removal systems can combat many of shows that in the case of catalytic and thermal debinding there exceptional corrosion resistance and the highest quality parts. the common problems part manufacturers face when looking to fulfil increasing capacity requirements are no appropriate solutions currently available to combine the Different sensitive products are produced in such furnaces, while also reducing manufacturing cost per part. Such technical advantages are crucial in staying two processes into a single device with a straightforward and including MIM stainless steels, foam materials, sintered aluminium ahead in the booming MIM industry. economically viable approach to commercial production. There parts, ultra-fine brazing products and even for standard sintered are a few manufacturers around the world who today are trying parts a high-level quality can be achieved using much cheaper to connect all the processes into a single device, but to-date the alloys due to the sintering temperature above 1250ºC. solutions are a compromise. It should be noted that the cost of purchasing a universal device is not much lower than the cost of purchasing two devices dedicated strictly to the given types of Acknowledgments processes. Further development work is ongoing to further increase The complete engineering work was done at Elino Industrie– As the MIM industry continues to grow and attract more interest 2. Chemical decomposition and discolouration by: cost-efficiency in terms of total operational cost, reduction in Ofenbau GmbH in Duren, Germany. Elino is the part of the PLC from a widening range of industries, the advantages of MIM a) Inaccurate process gas management consumption cost of industrial gases and increase in number of holding group which includes the companies Wistra (Germany/ technology have contributed to the increased demand for high- b) Binder re-deposition during the second debinding step cycles per day. China), Elmetherm (France/Germany), Wisconsin Oven (USA) quality MIM parts with tighter geometrical tolerances and ever c) Residual sintering furnace contamination The MIM-ECO CT and MIM-ECO VR batch furnaces and Mecarom (Romania). improving material properties. With the desirable benefits of supplement an existing and well-proven product range of Elino state-of-the-art MIM technology (e.g., capability of designing In addition to those technical limitations, highly competitive continuous furnaces for MIM which have been manufactured complex parts, cost-effective assembly, high-quality parts and market conditions put intense cost pressure on part manufacturers. since 2005. These continuous MIM furnaces consist of continuous enhanced production capacity) increasing in popularity, industry Thus, in order to drive the MIM industry forward, the need for more catalytic debinding systems and continuous thermal debinding and requirements have been outlined to ensure the increase in demand cost-efficient and technically improved production equipment and sintering systems. The continuous catalytic debinding furnace is does not lead to lackluster, rushed results. material is crucial. designed as complete gas tight system and operates at temperatures Higher power densities in modern car engines, power trains up to 160°C. It has a verified throughput rate as high as 50 kg/h and other mechanical machinery requires the miniaturisation and at 4 h effective debinding time. The design is based on a patented compaction of mechanical systems that offer greater potential for system, provides for a special cross convection system and innovative and cost-efficient production technologies. Furthermore, has shown to use 50% less in acid and nitrogen consumption in the enhanced functionality of intricate MIM parts can also lead production compared to conventional systems. The continuous to reduced assembly costs when mass producing products such catalytic debinding furnace can be linked to the succeeding as premium notebooks or mobile phones. However, to meet the continuous thermal debinding and sintering furnace. increasing technical requirements and specifications of the industry, It is the basic concept for our continuous furnaces to allow for the potential to further improve the accuracy and efficiency of the a strict separation of each individual process step and to assure MIM process equipment has to be exploited. Current limitations absolute clean and complete exchange of atmospheric conditions in terms of mechanical and chemical properties, as well as optical before the next process step is initiated. The experiences from the appearance, of the parts are determined, amongst others, by: operation of this continuous furnace product range led to the new concept for the above described batch furnace designs. 1. Inhomogeneous shrinkage (i.e., geometrical distortion) The continuous thermal debinding and sintering furnaces are caused by: separated by a gas-tight double-door lock chamber with purging a) Non-uniform powder and feedstock mixing system. The thermal debinding furnace is operated with high- b) Density fluctuations introduced during moulding and/or velocity gas flow. The sintering furnace has a fully muffled high the first debinding step Fig. 1 A typical MIM process, highlighting the different process modes temperature sintering zone. Both, the thermal debinding and the c) Inaccurate temperature uniformity in the sintering furnace used at different temperature levels

will help to reduce electrical power consumption. To keep design Hot zones and development costs reasonable, powerful CFD simulation tools A hot zone must have excellent temperature uniformity of no more were used to find optimised gas and heat flow patterns in modern and than +/-7 °F. This can be achieved by having multiple heat zones resource-saving vacuum MIM furnaces. and by utilising front and rear elements. Process gas management For fast-growing MIM companies looking for flexible is essential when it comes to protecting the hot zone from any production capacity and the ability to react quickly to changing binder wax contamination. Smart process control can be integrated market demands, long delivery times for production equipment within the furnace’s program to efficiently transport the gaseous can slow down growth. Usually, furnace manufacturers start material out of the hot zone, while minimising the consumption of producing equipment only after receiving an order, not keeping key the process gas being used. components and long lead time materials in stock. The resulting Binder removal can be achieved through the use of the high delivery times of nine to twelve months for new furnaces regularly pumping capacity of a booster and mechanical screw pump. lead to bottlenecks in MIM production lines when additional part Efficient pumping out of the hot zone area is realised through a orders have to be scheduled at short notice. Only recently have powerful pumping unit, which in this case consists of a vacuum lean manufacturing and standardised production concepts been booster (lobe pump) supported by a mechanical screw pump. introduced by leading vacuum furnace manufacturers to meet this rapid demand. Comparing hot zones Fig. 2 An Ipsen TITAN DS MIM vacuum furnace As mentioned above, one of the critical requirements in the MIM Furnace technology industry is the reduced cost of the initial investment and the power Fig. 4 Partial pressure gas diagram. During the debinding cycle, gas consumption of the furnace. is evacuated from the hot zone to the binder trap before going through Apart from tailor-made, highly specialised systems, most of However, some of the specialised MIM vacuum furnaces the pumping system. Wax is removed from the hot zone and collected the MIM sintering furnaces on the market can be subdivided combining the previously mentioned technical advantages are in the binder trap into vacuum batch or continuous atmospheric furnaces. Both limited to rather small usable volumes. Due to their disadvantageous Graphite technologies offer the possibility of integrating the thermal invest-to-capacity ratio and lower energy efficiency, sintering costs removal of residual polymer still contained in the brown parts after per part might consume potential savings realised in other MIM Less expensive to replace than molybdenum moulding and catalytic or solvent debinding. process steps. Easier to maintain For high volume MIM producers with correspondingly large More energy efficient (50% lower heat loss) lot sizes of identical or geometrically similar parts, the operation of a continuous atmospheric furnace may be appropriate if fully Ipsen’s MIM Technology Longer lifespans utilised. In this case, comparably low cycle time with high sintering The TITAN DS debinding and sintering furnace incorporates a Molybdenum capacities can result in a favourable cost-benefit ratio. However, number of cutting-edge technologies that allow MIM manufacturers with minimum annual production volumes in the range of 150 to 200 to compete in such a high-growth industry. Better leak rate metric tons, high investment costs and large footprints, continuous Minimises water absorption furnaces are not economical in small or medium lot production Temperature uniformity Suitable for titanium materials lines. Furthermore, they are still prone to longer downtimes for The temperature uniformity required by the industry is particularly Higher temperature applications – less risk of eutectic melting Fig. 3 The interior and hot zone of a TITAN DS vacuum furnace maintenance, causing reduced manufacturing agility. important for large volume furnaces. The TITAN DS work zone On the other hand, vacuum batch sintering furnaces, as offered by of 36” x 36” x 48” (910 mm x 910 mm x 1220 mm) and hearth Beside high purchasing prices for raw materials (e.g. fine- a number of commercial suppliers, allow for excellent control of the gross load weight capacity of 4000 pounds (1800 kg) have a Table 1 Hot zone benefit comparison grained metal powders, polymer binder systems and ready-to- debinding and sintering process. The aforementioned limitations, maximum operating temperature of 2550°F (1399°C) and a mold feedstock), high utility consumptions are among the major in terms of geometrical distortion and chemical composition of the burnout temperature of 2600°F (1427°C). Even with the large size pressure of up to 10 Torr. For quenching, it is equipped with a 30 cost drivers of the MIM process. Low investment and operating finished MIM parts, can be contained by for example sophisticated of the furnace, the temperature uniformity is within the required HP motor capable of cooling up to 2 bar with the option to select costs of debinding and sintering furnaces are therefore key to the gas management systems providing laminar flow of unloaded gas +/- 7°F through the use of Ipsen’s patented DigiTrim® software between nitrogen or argon gas. competitiveness of MIM part producers. Moreover, depending on to flush away outgassing binder material. Furthermore, by means technology which allows the user to control the power output of The intuitive VacuProf® control software also allows the user to the specific production situation of the individual manufacturer, the of the smaller hot zone volume, temperature uniformity in vacuum the furnace’s three heat zones at four different temperature ranges, choose a Purge Gas Mode and Roughing Modulating Line Mode. choice of the most suitable furnace technology is a prerequisite to furnaces can be extremely accurate and reach values as low as giving a flexibility to adjust uniformity at critical temperatures. The main purpose of the Purge Gas Mode is to eliminate binder becoming a successful player in the MIM industry. +/- 1K. In general, the superior cleanliness of the gas atmosphere, Front and rear elements are also utilized in order to achieve greater contamination inside the furnace. During this mode, we introduce the enhanced adjustability of the process parameters, as well uniformity. the process gas at two different locations: one outside the hot zone, The typical MIM process and MIM industry as the reduced vibration on the parts means that vacuum batch which always has the higher pressure, and the other inside the hot furnaces are the technology of choice when producing high-quality Hot zone design zone. Outside the hot zone, the process gas is introduced to prevent requirements components for, as an example, medical applications. The lower The hot zone is designed with two inches of graphite felt and backed binder contamination on the furnace wall. Since we are pumping A typical MIM process in a batch furnace uses the Purge Gas investment and higher cycle flexibility offer further advantages with a carbon steel plenum as a structure. The design also integrates from inside the hot zone, the gas will flow inwards and out of Mode during debinding temperature, followed by a Roughing when companies are facing volatile order situations and need to run a durable CFC hot face designed to take any undesired force such the pumping port inside the hot zone. The process gas inside the Line Mode used up into sintering temperatures. With the larger parts with different geometries and materials. Operating an array of as impact of parts during loading and unloading. Although not hot zone continuously moves the evaporated binder, avoiding re- furnace production lines, high quality is always a key requirement. vacuum furnaces not only provides a flexible and robust production required for the MIM process, the CFC lining is capable of taking deposition of the wax on the parts and the stacking system used to Therefore, accurate process control is critical throughout the cycle, line, but also offers the possibility to run largely deviating operating up to 12 bar range of quenching pressure, protecting the layers of support the parts. as well as cleanliness of parts, and scrap rate must be reduced and programs at the same time. the high-performance graphite felt. Robust, thick graphite elements The Roughing Modulating Valve Mode is used during a specific kept to a minimum. can also take some of the unavoidable force. part of the high temperature sintering stages. At this time, it is An important factor for cost-efficient MIM vacuum furnace A MIM furnace’s key components Three heat trim zones are used with a total of six complete loops assumed that all of the binder wax has been evaporated and purged operation is the economical consumption of process gas and electrical About 60% of commercial MIM part production uses stainless which are evenly distributed to provide optimum heating to the out of the hot zone. Therefore, operators pump straight through power. Depending on the gas type, these two large cost elements of steels. The most popular alloys are 17-4 PH and austenitic stainless work load. the roughing line bypassing the Binder Trap System. The purpose the sintering process can account for more than 50% of the total cost. steels 304L and 316L. Prices for commercially available, ready-to- of this valve is to control the partial pressure set point during the The adjustability of a Partial Pressure Mode with the lowest possible mould feedstock can be high and after moulding and debinding, the Process gas management sintering stages where there is minimal outgassing occurring in gas flow, while still enabling a contamination-free debinding and monetary value of the raw parts loaded into the furnace can exceed The TITAN DS can reach an ultimate vacuum level of less than <10 the furnace, slowing the pumping down to maintain a set point sintering operation, must be implemented. Low heat losses in a well- thousands of US dollars. Thus, the reliability and performance of a microns due to the booster and mechanical pump capability. Using at a constant flow rate of gas minimising the total consumption designed hot zone with an efficient set-up of optimised heat elements MIM furnace’s key components is essential. nitrogen, hydrogen and argon, the furnace is equipped with a partial throughout the remaining stages of the cycle.

92 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 © 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 93 Technical Paper | contents page | news | events | advertisers’ index | email | | contents page | news | events | advertisers’ index | email | european powder metallurgy association binder, is injected in the suction line of the vacuum booster and the connected screw pump. Rotational speed of the lobes or screws can be adjusted by means of a variable frequency drive to control liquid flow velocity and to ensure efficient washing out of the polymeric precipitations.

Conclusion INTERNATIONAL Modern vacuum furnaces featuring innovative technologies will improve the efficiency and competitiveness of the industrial MIM process. For its economic success, capital and operational costs of such specialised MIM furnaces must be kept within reasonable limits. With the demands on the MIM industry on CONGRESS & the rise, technologies such as those introduced in the TITAN DS furnace combat problems that may arise as customers look to meet increasing requirements and stay competitive, while also reducing the manufacturing cost per part in larger vacuum MIM furnaces. EXHIBITION 21 - 24 September 2014 The Messezentrum Salzburg, Austria

Fig. 5 Ipsen’s versatile binder traps are equipped with heating elements and quickly interchangeable collection bucket

Binder removal system After meticulous removal of the polymeric binder residues from the hot zone, continued efficient handling and filtration of the charged process gas is critical to avoid unwanted binder material buildup in pipes, valves or pumps. For an uninterrupted and low-maintenance operation, it is therefore essential to protect critical furnace components by means of an efficient binder trap system. With a pumping rate of 3000 cubic feet per minute (5097 cubic meters per hour), very little process gas is used during the debinding period of the cycle. To protect the pumps, an efficient binder trap system must be installed prior to the pumps to avoid binder contamination. This features a four-stage effluent trapping system. The first stage knocks down heavy particles and condenses volatile solids

and liquids on large surface areas. Stages two and three contain © www.christof-reich.com Copyright wire mesh screen elements strategically located to filter the binder gradually. The last stage is designed to trap any vapour molecules that might have passed the previous stages. The modular system is designed with heaters to dissolve trapped binder which is then collected in a collection bucket that can be easily removed and changed for cleaning. Even though the risk of contaminating the vacuum pumps is now reduced to a minimum, long-term buildup of binder deposits, for example on the lobes or casings, still can occur when continuously running the furnace in 24/7 operation. In order to maintain maximum pumping performance, fast-rotating parts assembled with minimal clearances need to be kept clean. An innovative cleaning concept based on software-controlled pump flushing procedures was recently tested in a new vacuum MIM furnace from Ipsen. Liquid solvent, capable of dissolving hardened polymeric Developing the Powder Metallurgy Future the Powder Developing 94 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Vol. 7 No. 3 www.epma.com/pm2014© 2013 Inovar Communications Ltd September 2013 Powder Injection Moulding International 95 Events / Advertisers | contents page | news | events | advertisers’ index | email |

Events Guide Advertisers’ Index

Advanced Materials Technologies Pte Ltd 36 2013 Advanced Metalworking Practices, LLC 4 AP&C Raymor Industries, Inc 21 APMA 2013 International PM Conference and Exhibition APMA 2013 Conference 56 November 3-6 Arburg GmbH & Co. KG Outside back cover Xiamen, China AT&M 18 www.apma2013.com Avure Technologies 15 BASF SE 7 Hagen Symposium (32nd) Carpenter Powder Products 24 November 28-29, 2013. Hagen, Germany Centorr Vacuum Industries, Inc. 22 www.pulvermetallurgie.com CM Furnaces, Inc. 20 Cremer Thermoprozessanlagen GmbH 12 2013 International Titanium Powder Processing, Elino Industrie-Ofenbau GmbH 16 Consolidation and Metallurgy Conference Elnik Systems 34 December 2-4 eMBe Products & Services GmbH 32 Waikato, New Zealand www.tida.co.nz Emery Oleochemicals GmbH 11 Euro PM2014 (EPMA) 95 Epson Atmix 9 2014 Erasteel 2 Erowa 23 PM14 - International Conference on Powder Metallurgy and Particulate Materials & Exhibition FCT Anlagenbau GmbH 38 January 23-25, Chennai, India Formatec Ceramics 26 www.pmai.in/pm14 Hardex 36 HIP 2014 International Conference 55 MIM 2014 International Titanium Powder Conference (TIDA) 45 February 24-26 Ipsen Inc 19 Long Beach, California, USA www.mpif.org Kerafol GmbH 30 Kinetics 25 10th International Conference on the Science of Hard LÖMI GmbH 6 Materials (ICSHM10) Megamet Solid Metals, Inc 31 March 10 - 14 MIM2014 International Conference 46 Cancun, Mexico Nabertherm GmbH 5 www.icshm10.org Novamet Specialty Products Corp 8 PM China 2014 - International Power Metallurgy Orton Ceramics 27 Exhibition & Conference Parmatech 35 April 27-29, PM China 2014 54 Shanghai, China PM 2014 World Congress Inside back cover www.cn-pmexpo.com PolyMIM GmbH 29

PM2014 World Congress Phoenix Scientific Industries Ltd 22 May 18–22 Sandvik Osprey Ltd 13 Orlando, Florida, USA Seco/Warwick Group 33 www.mpif.org Sunrock Ceramics 17 TAV S.p.A. 10 HIP 2014, 11th International HIP Conference TD Molybdenum & Tungsten Manufacturing LLC 28 June 9 -13, 2014 Stockholm, Sweden Teibow Co., Ltd. 28 www.hip14.se Tisoma 30 United States Metal Powders, Inc. Inside front cover Sintering 2014 Winkworth 26 August 24-28 Dresden, Germany Wittmann Battenfeld GmbH 37 www.sintering2014.com Yuelong Superfine Metal Co. Ltd. 14

96 Powder Injection Moulding International September 2013 © 2013 Inovar Communications Ltd Vol. 7 No. 3 Five decades of PIM power! This means technological advances and practical expertise for your high-quality series production. With internationally acclaimed specialists and sophisticated technology. With competent partners and a dedicated PIM laboratory, in which VJGGPVKTGRTQFWEVKQPRTQEGUUECPDGECTTKGFQWV$GPGƂVHTQO#4$74)oU[GCTUQH2+/GZRGTVKUG

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ARBURG GmbH + Co KG Postfach 11 09 · 72286 Lossburg / Germany Tel.: +49 (0) 74 46 33-0 Fax: +49 (0) 74 46 33 33 65 e-mail: [email protected] www.arburg.com