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Handbook of metal injection moldingEdited by D Heaney, Penn State University, USA
Woodhead Publishing Series in Metals and Surface Engineering No. 54
This new book will be a most useful reference tool for MIM researchers, producers and end-users alike.
Power Injection Moulding International
- provides an authoritative guide to metal injection molding and its applications
- discusses the fundamentals of the metal injection molding processes and covers topics such as component design, important powder characteristics, compound manufacture, tooling design, molding optimization, debinding, and sintering
- comprehensively examines quality issues such as feedstock characterization, modeling and simulation, common defects and carbon content control
- reviews special metal injection molding processes and metal injection molding of specific materials, including stainless steels, titanium and heavy alloys
Metal injection molding combines the most useful characteristics of powder metallurgy and plastic injection molding to facilitate the production of small, complex-shaped metal components with outstanding mechanical properties. The Handbook of metal injection molding provides an authoritative guide to this important technology and its applications.
Part one discusses the fundamentals of the metal injection molding process with chapters on topics such as component design, important powder characteristics, compound manufacture, tooling design, molding optimization, debinding, and sintering. Part two provides a detailed review of quality issues, including feedstock characterisation, modeling and simulation, methods to qualify a MIM process, common defects and carbon content control. Special metal injection molding processes are the focus of part three, which provides comprehensive coverage of micro components, two material/two color structures, and porous metal techniques. Finally, part four explores metal injection molding of particular materials, including stainless steels, titanium and titanium alloys, thermal management alloys, high speed tool steels, heavy alloys, refractory metals, hard metals and soft magnetic alloys.
With its distinguished editor and expert team of international contributors, the Handbook of metal injection molding is an essential guide for all those involved in the high-volume manufacture of small precision parts, across a wide range of high-tech industries such as microelectronics, biomedical and aerospace engineering.
ISBN 0 85709 066 6
ISBN-13: 978 0 85709 066 9
June 2012
612 pages 234 x 156mm hardback
£170.00 / US$290.00 / €205.00
Usually dispatched within 24 hours
About the editor
Donald F. Heaney is the President and CEO of Advanced Powder Products Inc., USA. He is also the Director of the Center for Innovative Sintered Products, and Associate Professor of Engineering Science and Mechanics at The Pennsylvania State University.
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Contents
PART 1 PROCESSING
PART 2 QUALITY ISSUES
PART 3 SPECIAL METAL INJECTION MOLDING PROCESSES
PART 4 METAL INJECTION MOLDING OF SPECIFIC MATERIALS
Metal powder injection molding (MIM): key trends and markets
R M German, San Diego State University, USA
- Introduction and background
- History of success
- Industry structure
- Statistical highlights
- Industry shifts
- Sales situation
- Market statistics
- Metal powder injection molding market by region
- Metal powder injection molding market by application
- Market opportunities
- Production sophistication
- Conclusion
- Sources of further information
Metal powder injection molding (MIM): key trends and markets
R M German, San Diego State University, USA
- Introduction and background
- History of success
- Industry structure
- Statistical highlights
- Industry shifts
- Sales situation
- Market statistics
- Metal powder injection molding market by region
- Metal powder injection molding market by application
- Market opportunities
- Production sophistication
- Conclusion
- Sources of further information
PART 1 PROCESSING
Designing for metal injection molding (MIM)
D F Heaney, Advanced Powder Products, Inc, USA
- Introduction
- Available materials and properties
- Dimensional capability
- Surface finish
- Tooling artifacts
- Design considerations
- References and further reading
Powders for metal injection molding (MIM)
D F Heaney, Advanced Powder Products, Inc, USA
- Introduction
- Ideal MIM powder characteristics
- Characterizing MIM powders
- Different MIM powder fabrication techniques
- Different alloying methods
- References
Powder binder formulation and compound manufacture in metal injection molding (MIM)
R K Enneti, Global Tungsten and Powders, V P Onbattuvelli and S V Atre, Oregon State University, USA
- Introduction: the role of binders
- Binder chemistry and constituents
- Binder properties and effects on feedstock
- Mixing technologies
- Case studies: lab scale and commercial formulations
- References
Tooling for metal injection molding (MIM)
G Schlieper, Gammatec Engineering, Germany
- Introduction
- General design and function of injection molding machines
-
Elements of the tool set
- Tool design options
- Special features and instrumentation
- Supporting software and economic aspects
- References
Molding of components in metal injection molding (MIM)
D F Heaney, Advanced Powder Products, Inc, and C D Greene, Treemen Industries, Inc, USA
- Introduction
- Equipment
- Injection molding equipment
- Auxiliary equipment
- Injection molding process
- Common defects in MIM
- References
Debinding and sintering of metal injection molding (MIM) components
S Banerjee, DSH Technologies LLC and C J Joens, Elnik Systems LLC, USA
- Introduction
- Primary debinding
- Secondary debinding
- Sintering
- MIM materials
- Settering
- MIM furnaces
- Furnace profiles
- Summary
- Acknowledgements
- References
PART 2 QUALITY ISSUES
Characterisation of feedstock in metal injection molding (MIM)
H Lobo, DatapointLabs, USA
- Introduction
- Rheology
- Thermal analysis
- Thermal conductivity
- Pressure-volume-temperature (PVT)
- Conclusion
- Acknowledgements
- References
Modeling and simulation of metal injection molding (MIM)
T G Kang, Korea Aerospace University, Korea, Pusan National University, Republic of Korea (South), 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
- Modeling and simulation of the mixing process
- Modeling and simulation of the injection molding process
- Modeling and simulation of the thermal debinding process
- Modeling and simulation of the sintering process
- Conclusion
- References
Common defects in metal injection molding (MIM)
K S Hwang, National Taiwan University, Taiwan
- Introduction
- Feedstock
- Molding
- Debinding
- Sintering
- Conclusion
- References
Qualification of metal injection molding (MIM)
D F Heaney, Advanced Powder Products, Inc, USA
- Introduction
- The metal injection molding process
- Product qualification method
- MIM prototype methodology
- Process control
- Control parameter understanding
- Conclusion
- Sources of further information
Control of carbon content in metal injection molding (MIM)
G Herranz, Universidad de Castilla-La Mancha, Spain
- Introduction: the importance of carbon control
- Methods of controlling carbon, binder elimination and process parameters affecting carbon control
- Control of carbon in particular materials
- Material properties affected by carbon content
- References
PART 3 SPECIAL METAL INJECTION MOLDING PROCESSES
Micro metal injection molding (MicroMIM)
V Piotter, Karlsruhe Institute of Technology (KIT), Germany
- Introduction
- Potential of powder injection molding for micro technology
- Micro-manufacturing methods for tool making
- Powder injection molding of micro components
- Multi-component micro powder injection molding
- Simulation of MicroMIM
- Conclusion and future trends
- Sources of further information and advice
- References
Two-material/two-colour powder metal injection molding (2C-PIM)
P Suri, Heraeus Materials Technology LLC, USA
- Introduction
- Injection molding technology
- Debinding and sintering
- C-PIM products
- Future trends
- References
Powder space holder metal injection molding (PSH-MIM) of micro-porous metals
K Nishiyabu, Kinki University, Japan
- Introduction
- Production methods for porous metals
- Formation of micro-porous structures by the PSH method
- Control of porous structure with the PSH method
- Liquid infiltration properties of micro-porous metals produced by the PSH method
- Dimensional accuracy of micro-porous MIM parts
- Functionally graded structures of micro-porous metals
- Conclusion
- Acknowledgement
- References
PART 4 METAL INJECTION MOLDING OF SPECIFIC MATERIALS
Metal injection molding (MIM) of stainless steels
J M Torralba, Institute IMDEA Materials, Universidad Carlos III de Madrid, Spain
- Introduction
- Stainless steels in metal injection moulding
- Applications of MIM stainless steels
- Acknowledgements
- References
Metal injection molding (MIM) of titanium and titanium alloys
T Ebel, Helmholtz-Zentrum Geesthacht, Germany
- Introduction
- Challenges of MIM of titanium
- Basics of processing
- Mechanical properties
- Cost reduction
- Special applications
- Conclusion and future trends
- Sources of further information
- References
Metal injection molding (MIM) of thermal management materials in microelectronics
J L Johnson, ATI Firth Sterling, USA
- Introduction
- Heat dissipation in microelectronics
- Copper
- Tungsten-copper
- Molybdenum-copper
- Conclusions
- References
Metal injection molding (MIM) of soft magnetic materials
H Miura, Kyushu University, Japan
- Introduction
- Fe-Si
- Fe-Si-Al
- Fe-Ni
- Conclusion
- References
Metal injection molding (MIM) of high speed tool steels
N S Myers, Kennametal Inc, and D F Heaney, Advanced Powder Products, Inc, USA
- Introduction
- Tool steel MIM processing
- Mechanical properties
- References
Metal injection molding of heavy alloys, refractory metals, and hard metals
J L Johnson, ATI Firth Sterling, D F Heaney, Advanced Powder Products, Inc, and N S Myers, Kennametal Inc, USA
- Introduction
- Applications
- Feedstock formulation concerns
- Heavy alloys
- Refractory metals
- Hardmetals
- References