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1 Metal powder injection molding(MIM):key trends and markets&R.M.GERMAN,San Diego State University,USA1

1.1 Introduction and background1

1.2 History of success2

1.3 Industry structure4

1.4 Statistical highlights6

1.5 Industry shifts9

1.6 Sales situation10

1.7 Market statistics12

1.8 Metal powder injection molding market by region13

1.9 Metal powder injection molding market by application14

1.10 Market opportunities15

1.11 Production sophistication21

1.12 Conclusion23

1.13 Sources of further information23

Part Ⅰ Processing27

2 Designing for metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA29

2.1 Introduction29

2.2 Available materials and properties31

2.3 Dimensional capability35

2.4 Surface finish35

2.5 Tooling artifacts35

2.6 Design considerations40

2.7 Sources of further information49

3 Powders for metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA50

3.1 Introduction50

3.2 Ideal MIM powder characteristics51

3.3 Characterizing MIM powders55

3.4 Different MIM powder fabrication techniques57

3.5 Different alloying methods61

3.6 References62

4 Powder binder formulation and compound manufacture in metal injection molding(MIM)&R.K.ENNETI,Global Tungsten and Powders,USA and V.P.ONBATTUVELLI and S.V.ATRE,Oregon State University,USA64

4.1 Introduction:the role of binders64

4.2 Binder chemistry and constituents66

4.3 Binder properties and effects on feedstock70

4.4 Mixing technologies84

4.5 Case studies:lab scale and commercial formulations88

4.6 References89

5 Tooling for metal injection molding(MIM)&G.SCHLIEPER,Gammatec Engineering GmbH,Germany93

5.1 Introduction93

5.2 General design and function of injection molding machines94

5.3 Elements of the tool set96

5.4 Tool design options98

5.5 Special features and instrumentation104

5.6 Supporting software and economic aspects106

5.7 Sources of further information108

6 Molding of components in metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA and C.D.GREENE,Treemen Industries,Inc.,USA109

6.1 Introduction109

6.2 Injection molding equipment110

6.3 Auxiliary equipment115

6.4 Injection molding process116

6.5 Common defects in MIM129

6.6 References131

7 Debinding and sintering of metal injection molding(MIM)components&S.BANERJEE,DSH Technologies LLC,USA and C.J.JOENS,Elnik Systems LLC,USA133

7.1 Introduction133

7.2 Primary debinding136

7.3 Secondary debinding144

7.4 Sintering147

7.5 MIM materials161

7.6 Settering167

7.7 MIM furnaces169

7.8 Furnace profiles176

7.9 Summary176

7.10 Acknowledgements178

7.11 References178

Part Ⅱ Quality issues181

8 Characterization of feedstock in metal injection molding(MIM)&H.LOBO,DatapointLabs,USA183

8.1 Introduction183

8.2 Rheology186

8.3 Thermal analysis190

8.4 Thermal conductivity193

8.5 Pressure-volume-temperature (PVT)194

8.6 Conclusions195

8.7 Acknowledgments196

8.8 References196

9 Modeling and simulation of metal injection molding(MIM)&T.G.KANG,Korea Aerospace University,Korea,S.AHN,Pusan National University,Korea,S.H.CHUNG,Hyundai Steel Co.,Korea,S.T.CHUNG,CetaTech Inc.,Korea,Y.S.KWON,CetaTech,Inc.,Korea,S.J.PARK,POSTECH,Korea and R.M.GERMAN,San Diego State University,USA197

9.1 Modeling and simulation of the mixing process197

9.2 Modeling and simulation of the injection molding process203

9.3 Modeling and simulation of the thermal debinding process215

9.4 Modeling and simulation of the sintering process224

9.5 Conclusion230

9.6 References231

10 Common defects in metal injection molding(MIM)&K.S.HWANG,National Taiwan University,Taiwan,R.O.C.235

10.1 Introduction235

10.2 Feedstock236

10.3 Molding238

10.4 Debinding243

10.5 Sintering250

10.6 Conclusion251

10.7 References252

11 Qualification of metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA254

11.1 Introduction254

11.2 The metal injection molding process255

11.3 Product qualification method255

11.4 MIM prototype methodology257

11.5 Process control258

11.6 Understanding of control parameters260

11.7 Conclusion263

11.8 Sources of further information263

12 Control of carbon content in metal injection molding(MIM)&G.HERRANZ,Universidad de Castilla-La Mancha,Spain265

12.1 Introduction:the importance of carbon control265

12.2 Methods of controlling carbon,binder elimination and process parameters affecting carbon control267

12.3 Control of carbon in particular materials276

12.4 Material properties affected by carbon content297

12.5 References297

Part Ⅲ Special metal injection molding processes305

13 Micro metal injection molding(MicroMIM)&V.PIOTTER,Karlsruhe Institute of Technology(KIT),Germany307

13.1 Introduction307

13.2 Potential of powder injection molding for micro-technology308

13.3 Micro-manufacturing methods for tool making309

13.4 Powder injection molding of micro components313

13.5 Multi-component micro powder injection molding325

13.6 Simulation of MicroMIM328

13.7 Conclusion and future trends330

13.8 Sources of further information and advice331

13.9 References332

14 Two-material/two-color powder metal injection molding (2C-PIM)&P.SURI,Heraeus Materials Technology LLC,USA338

14.1 Introduction338

14.2 Injection molding technology338

14.3 Debinding and sintering341

14.4 2C-PIM products344

14.5 Future trends346

14.6 References347

15 Powder space holder metal injection molding(PSH-MIM)of micro-porous metals&K.NISHIYABU,Kinki University,Japan349

15.1 Introduction349

15.2 Production methods for porous metals351

15.3 Formation of micro-porous structures by the PSH method354

15.4 Control of porous structure with the PSH method360

15.5 Liquid infiltration properties of micro-porous metals produced by the PSH method369

15.6 Dimensional accuracy of micro-porous MIM parts374

15.7 Functionally graded structures of micro-porous metals379

15.8 Conclusion388

15.9 Acknowledgements388

15.10 References389

Part Ⅳ Metal injection molding of specific materials391

16 Metal injection molding(MIM)of stainless steels&J.M.TORRALBA,Institute IMDEA Materials,Universidad Carlos Ⅲ de Madrid,Spain393

16.1 Introduction393

16.2 Stainless steels in metal injection molding(MIM)396

16.3 Applications of MIM stainless steels403

16.4 Acknowledgements409

16.5 References410

17 Metal injection molding(MIM)of titanium and titanium alloys&T.EBEL,Helmholtz-Zentrum Geesthacht,Germany415

17.1 Introduction415

17.2 Challenges of MIM of titanium416

17.3 Basics of processing422

17.4 Mechanical properties425

17.5 Cost reduction432

17.6 Special applications435

17.7 Conclusion and future trends440

17.8 Sources of further information441

17.9 References441

18 Metal injection molding(MIM)of thermal management materials in microelectronics&J.L.JOHNSON,ATI Firth Sterling,USA446

18.1 Introduction446

18.2 Heat dissipation in microelectronics447

18.3 Copper451

18.4 Tungsten-copper461

18.5 Molybdenum-copper474

18.6 Conclusions482

18.7 References482

19 Metal injection molding(MIM)of soft magnetic materials&H.MIURA,Kyushu University,Japan487

19.1 Introduction487

19.2 Fe-6.5Si489

19.3 Fe-9.5Si-5.5Al497

19.4 Fe-50Ni506

19.5 Conclusion513

19.6 References514

20 Metal injection molding(MIM)of high-speed tool steels&N.S.MYERS,Kennametal Inc.,USA and D.F.HEANEY,Advanced Powder Products,Inc.,USA516

20.1 Introduction516

20.2 Tool steel MIM processing517

20.3 Mechanical properties523

20.4 References525

21 Metal injection molding(MIM)of heavy alloys,refractory metals,and hardmetals&J.L.JOHNSON,ATI Firth Sterling,USA,D.F.HEANEY,Advanced Powder Products,Inc.,USA and N.S.Myers,Kennametal Inc.,USA526

21.1 Introduction526

21.2 Applications527

21.3 Feedstock formulation concerns529

21.4 Heavy alloys534

21.5 Refractory metals544

21.6 Hardmetals554

21.7 References560

Index569