金属注射成形手册 影印版PDF格式文档图书下载

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

1.1 Introduction and background 1

1.2 History of success 2

1.3 Industry structure 4

1.4 Statistical highlights 6

1.5 Industry shifts 9

1.6 Sales situation 10

1.7 Market statistics 12

1.8 Metal powder injection molding market by region 13

1.9 Metal powder injection molding market by application 14

1.10 Market opportunities 15

1.11 Production sophistication 21

1.12 Conclusion 23

1.13 Sources of further information 23

Part Ⅰ Processing 27

2 Designing for metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA 29

2.1 Introduction 29

2.2 Available materials and properties 31

2.3 Dimensional capability 35

2.4 Surface finish 35

2.5 Tooling artifacts 35

2.6 Design considerations 40

2.7 Sources of further information 49

3 Powders for metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA 50

3.1 Introduction 50

3.2 Ideal MIM powder characteristics 51

3.3 Characterizing MIM powders 55

3.4 Different MIM powder fabrication techniques 57

3.5 Different alloying methods 61

3.6 References 62

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,USA 64

4.1 Introduction:the role of binders 64

4.2 Binder chemistry and constituents 66

4.3 Binder properties and effects on feedstock 70

4.4 Mixing technologies 84

4.5 Case studies:lab scale and commercial formulations 88

4.6 References 89

5 Tooling for metal injection molding(MIM)&G.SCHLIEPER,Gammatec Engineering GmbH,Germany 93

5.1 Introduction 93

5.2 General design and function of injection molding machines 94

5.3 Elements of the tool set 96

5.4 Tool design options 98

5.5 Special features and instrumentation 104

5.6 Supporting software and economic aspects 106

5.7 Sources of further information 108

6 Molding of components in metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA and C.D.GREENE,Treemen Industries,Inc.,USA 109

6.1 Introduction 109

6.2 Injection molding equipment 110

6.3 Auxiliary equipment 115

6.4 Injection molding process 116

6.5 Common defects in MIM 129

6.6 References 131

7 Debinding and sintering of metal injection molding(MIM)components&S.BANERJEE,DSH Technologies LLC,USA and C.J.JOENS,Elnik Systems LLC,USA 133

7.1 Introduction 133

7.2 Primary debinding 136

7.3 Secondary debinding 144

7.4 Sintering 147

7.5 MIM materials 161

7.6 Settering 167

7.7 MIM furnaces 169

7.8 Furnace profiles 176

7.9 Summary 176

7.10 Acknowledgements 178

7.11 References 178

Part Ⅱ Quality issues 181

8 Characterization of feedstock in metal injection molding(MIM)&H.LOBO,DatapointLabs,USA 183

8.1 Introduction 183

8.2 Rheology 186

8.3 Thermal analysis 190

8.4 Thermal conductivity 193

8.5 Pressure-volume-temperature (PVT) 194

8.6 Conclusions 195

8.7 Acknowledgments 196

8.8 References 196

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,USA 197

9.1 Modeling and simulation of the mixing process 197

9.2 Modeling and simulation of the injection molding process 203

9.3 Modeling and simulation of the thermal debinding process 215

9.4 Modeling and simulation of the sintering process 224

9.5 Conclusion 230

9.6 References 231

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

10.1 Introduction 235

10.2 Feedstock 236

10.3 Molding 238

10.4 Debinding 243

10.5 Sintering 250

10.6 Conclusion 251

10.7 References 252

11 Qualification of metal injection molding(MIM)&D.F.HEANEY,Advanced Powder Products,Inc.,USA 254

11.1 Introduction 254

11.2 The metal injection molding process 255

11.3 Product qualification method 255

11.4 MIM prototype methodology 257

11.5 Process control 258

11.6 Understanding of control parameters 260

11.7 Conclusion 263

11.8 Sources of further information 263

12 Control of carbon content in metal injection molding(MIM)&G.HERRANZ,Universidad de Castilla-La Mancha,Spain 265

12.1 Introduction:the importance of carbon control 265

12.2 Methods of controlling carbon,binder elimination and process parameters affecting carbon control 267

12.3 Control of carbon in particular materials 276

12.4 Material properties affected by carbon content 297

12.5 References 297

Part Ⅲ Special metal injection molding processes 305

13 Micro metal injection molding(MicroMIM)&V.PIOTTER,Karlsruhe Institute of Technology(KIT),Germany 307

13.1 Introduction 307

13.2 Potential of powder injection molding for micro-technology 308

13.3 Micro-manufacturing methods for tool making 309

13.4 Powder injection molding of micro components 313

13.5 Multi-component micro powder injection molding 325

13.6 Simulation of MicroMIM 328

13.7 Conclusion and future trends 330

13.8 Sources of further information and advice 331

13.9 References 332

14 Two-material/two-color powder metal injection molding (2C-PIM)&P.SURI,Heraeus Materials Technology LLC,USA 338

14.1 Introduction 338

14.2 Injection molding technology 338

14.3 Debinding and sintering 341

14.4 2C-PIM products 344

14.5 Future trends 346

14.6 References 347

15 Powder space holder metal injection molding(PSH-MIM)of micro-porous metals&K.NISHIYABU,Kinki University,Japan 349

15.1 Introduction 349

15.2 Production methods for porous metals 351

15.3 Formation of micro-porous structures by the PSH method 354

15.4 Control of porous structure with the PSH method 360

15.5 Liquid infiltration properties of micro-porous metals produced by the PSH method 369

15.6 Dimensional accuracy of micro-porous MIM parts 374

15.7 Functionally graded structures of micro-porous metals 379

15.8 Conclusion 388

15.9 Acknowledgements 388

15.10 References 389

Part Ⅳ Metal injection molding of specific materials 391

16 Metal injection molding(MIM)of stainless steels&J.M.TORRALBA,Institute IMDEA Materials,Universidad Carlos Ⅲ de Madrid,Spain 393

16.1 Introduction 393

16.2 Stainless steels in metal injection molding(MIM) 396

16.3 Applications of MIM stainless steels 403

16.4 Acknowledgements 409

16.5 References 410

17 Metal injection molding(MIM)of titanium and titanium alloys&T.EBEL,Helmholtz-Zentrum Geesthacht,Germany 415

17.1 Introduction 415

17.2 Challenges of MIM of titanium 416

17.3 Basics of processing 422

17.4 Mechanical properties 425

17.5 Cost reduction 432

17.6 Special applications 435

17.7 Conclusion and future trends 440

17.8 Sources of further information 441

17.9 References 441

18 Metal injection molding(MIM)of thermal management materials in microelectronics&J.L.JOHNSON,ATI Firth Sterling,USA 446

18.1 Introduction 446

18.2 Heat dissipation in microelectronics 447

18.3 Copper 451

18.4 Tungsten-copper 461

18.5 Molybdenum-copper 474

18.6 Conclusions 482

18.7 References 482

19 Metal injection molding(MIM)of soft magnetic materials&H.MIURA,Kyushu University,Japan 487

19.1 Introduction 487

19.2 Fe-6.5Si 489

19.3 Fe-9.5Si-5.5Al 497

19.4 Fe-50Ni 506

19.5 Conclusion 513

19.6 References 514

20 Metal injection molding(MIM)of high-speed tool steels&N.S.MYERS,Kennametal Inc.,USA and D.F.HEANEY,Advanced Powder Products,Inc.,USA 516

20.1 Introduction 516

20.2 Tool steel MIM processing 517

20.3 Mechanical properties 523

20.4 References 525

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.,USA 526

21.1 Introduction 526

21.2 Applications 527

21.3 Feedstock formulation concerns 529

21.4 Heavy alloys 534

21.5 Refractory metals 544

21.6 Hardmetals 554

21.7 References 560

Index 569

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