North American MIM Review European MIM Review Asian

North American MIM Review
Bruce Dionne, MIMA President, Ruger Precision Metals, LLC.
The North American MIM industry is doing quite well. Industry statistics show that sales of MIM products
grew steadily over the past few years and optimism is high that further growth will be sustained. The
MIMA presentation made at November 2014’s PM Management Summit will be the basis of this
presentation.
European MIM Review
Keith Murray and Martin Kearns, Sandvik Osprey Ltd., United Kingdom
The European MIM industry continues to grow with a focus on the automotive industry, currently
estimated at over 50% of the European MIM market. Raw material fluctuations continue to impact
metalworking processes, favoring MIM’s net-shape appeal.
Asian MIM Review
To be determined.
Abstract not available.
New Titanium Alloy Feedstock for High Performance MIM
Toby Tingskog, Frederic Larouche, AP&C (Advanced Powders & Coatings) and Louis-Philippe
Lefebvre, Eric Baril, National Research Council Canada
Titanium alloys have great potential for Metal Injection Molding of high performance parts in Automotive,
Aerospace, 3C and sporting goods. A new feedstock has been developed that incorporates pre-alloyed Ti
6-4 and discrete additions that enhance properties. Processing and sintering parameters are presented
together with mechanical and metallurgical properties of completed parts.
Deformation Behavior Study of MIM Tungsten Heavy Alloy
David Chen, FloMet LLC, An ARCMIM Company
The experiments studies MIM Tungsten heavy alloy distortion behavior at different sintering
temperatures, sintering times and part geometries.
HIP for MIM Parts
Magnus Ahlfors, Avure Technologies AB and Anders Eklund, Quintus Technologies, LLC (Part
of the Avure Technologies Group), Sweden
MIM is an excellent process to produce smaller parts in large numbers for many industries, i.e.
Automotive, Medical, Dental and Aerospace.
However, even after the final sintering residual pores exist within the material. To remove these pores,
Hot Isostatic Pressing or HIP is the obvious choice. By applying a HIP step, pores will be eliminated and
the density will increase to virtually 100% of theoretical density. This pore elimination will improve the
strength, ductility and especially the fatigue properties of the material and residual stresses will also be
eliminated.
Today, it is possible to combine HIP processing and heat treatment in a specifically designed HIP
equipped with Uniform Rapid Quenching (URQ®) or Uniform Rapid Cooling (URC®). This paper will
describe the process and benefits of HIP for MIM parts together with the possibilities and advantages of
combining the HIP process and heat treatment in a URQ® HIP.
Microstructural Behavior of Sintered T42 High Speed Steel by Powder Injection
Molding (PIM)
Jong-Pil Lee, Dong-Kyu Park and In-Shup Ahn, School of Nano & Advanced Meterial Science
and Engineering, ReCAPT Gyeonsang National University, Korea
From the view of high speed steel (HSS) microstructure specifically used as a cutting tools and wear
parts, which can be described as metallic matrix composites formed by a ferrous with a dispersion of hard
and wear resistant carbides. The experimental specimens were manufactured using the PIM with T42
powders (50~80 vol.%) and multi-binder (20~50 vol.%).
The green parts were debound in n-hexan solution at 60℃ for 8 hours and thermal debound at N2-H2
mixed gas atmosphere for 8 hours. When sintering at 1240 ℃ in high vacuum, the specimen had highest
hardness (520 Hv). In addition, the tempered specimens were heated at N2 atmosphere from 540 to
560℃ for 60min. The oil quenched and tempered specimen at 560 ℃, has two kinds of homogeneously
distributed carbides (MC and M6C) precipitation, as a matter of course, the highest hardness of 812 Hv
was obtained in this study.
Solid Loading Optimization of Feedstock based on an Eco-Friendly Binder
System for Powder Injection Molding of Zircon
C. Abajo, A. Jiménez-Morales, J. M. Torralba, Materials Science and Engineering Department,
Universidad Carlos III of Madrid, F. Sket, IMDEA Materials Institute, O. López, MIM TECH
ALFA, P. P. Rodríguez, U. Andrés, ALFA INVESTIGACIÓN, DESARROLLO E NOVACIÓN,
AIE, & V. Bargués, GUZMÁN GLOBAL, SL, Pol. Ind. La Mina, Spain
The key to success in powder injection molding is to start the process with a high quality and optimized
feedstock composition. Homogeneity and an optimal solid loading are crucial to achieve the best
properties after moulding, debinding and sintering stages. The purpose of this study is to prove
conventional methodologies using extremely irregular powders of zircon and an eco-friendly feedstock
based on polyethylene glycol and cellulose acetate butyrate. Solid loading have been optimized by
numerous methods: oil absorption method, torque rheometry, density measurements, capillary rheometry,
tomography of injected samples, study of dimensional changes, distortion and mechanical properties. All
of them have been required to fully optimize the solid loading, since the conventional ones (torque
rheomety and density measurements) have not been useful to determine it testing this feedstock. A quite
high solid loading (58-60vol.%) have been achieved for this new eco-friendly feedstock for powder
injection molding of zircon.
Studies on the Effects of Nb on Sintering and Properties of MIM 440C
made by Prealloy and Master Alloy Routes
Martin A. Kearns, Keith Murray, Paul A Davies, Viacheslav Ryabinin, Sandvik Osprey Ltd.,
United Kingdom, and Erainy Gonzalez, TCK S.A., Dominican Republic
MIM is used for the production of an increasing variety of components for diverse applications. One of the
most versatile alloys in use is 440C martensitic stainless steel which offers high hardness and good
corrosion resistance. This combination makes the alloy suitable for automotive fuel injector parts, medical
pliers and a range of tool parts. Achieving reproducible properties and consistent hardness requires close
control of carbon levels in particular.
There are a number of variants on 440C in use today: some with enhanced carbon levels to achieve
higher hardness and some with additions of Nb which is claimed to increase the sintering process window
for the alloy. In this study, we examine the sintering behaviour at different temperatures of 440C and
440C + Nb made by prealloy and master alloy routes. Differences in hardness and mechanical properties
are discussed with reference to chemistry and microstructures of sintered parts.
Super Abrasive Machining as a Disruptive Technology
Rocco Petrilli, Super Abrasive Machining Innovations LLC (SAMI)
The disruptive nature of SAMI finds its soul in breaking decades-old paradigms of “doing things the way
we’ve always done them” and playing it safe and staying “inside the box”. It’s not that experienced
professionals in the automotive and related industries intentionally rely on more costly, more unreliable
approaches to components manufacture, it’s that they either don’t know about the alternative or are
fearful of “taking a chance” in the growingly risk adverse environment in which they operate . The same
is even more of an issue as baby boomers retire and the ranks of design engineers and procurement
teams
are filled with younger specialists, whose depth of experience in industry is far less extensive.
A disruptive innovation is an innovation that helps create a new market or value network, and eventually
disrupts an existing market and value network displacing an earlier technology. Proper placement of the
SAMI process in a near net shape metal forming sequence changes every aspect of the process design
including raw material formulation, tool design, reduced processing steps, component processing
controls, quality controls and final product assurance steps. Each of these changes drive previous
incurred
costs to the bottom line in quantities that quickly surpass the cost of the added SAM operation. SAMI’s
inherent ability to drive “upstream and downstream near net shape process cost reduction” by
significantly simplifying and enhancing the process cost effectiveness further promotes its use.
This manuscript details how and why SAMI is disruptive in its application by fully qualifying of the
process technology’s conformance to the term.
Continuous Vacuum Sintering Furnace
Pietro Tonini, TAV Vacuum Furnaces, Italy
A continuous vacuum sintering furnace provides a number of advantages when compared with batch type
equipment : very high production capability, significant energy savings, the possibility to fit the sintering
furnace within a lean type production system.
TAV has developed and manufactured an innovative concept for a continuous vacuum sintering furnace,
which suits a wide range of applications including sintering of MIM parts as well as of Tungsten Carbide
parts.
Opportunities in Particulate Composites
Randall M. German, San Diego State University
Since early PIM production in the mid-1980s, most success has been with monolithic materials – iron,
steel, nickel, copper, stainless steel, alumina, and titanium. There are many competitive fabrication
approaches for these materials, so PIM succeeds when it is relatively low in cost for a complex shape,
especially when compared to alternative fabrication routes. On the other hand particulate composites are
long known via sintering technologies and contribute probably $20 billion to global sales typically by
press-sinter routes compared to PIM at about $1.5 billion. Example particulate composites include
cemented carbides (WC-Co), cermets (Fe-TiC), thermal management (W-Cu), electronic contacts (AgCdO), light weight ceramic-metal combinations (Al-SiC), heavy alloys (W-Cu-Ni), and two-phase magnets
(FeNdB). Data on particulate composites by PIM show many early success. The market size and possible
benefits from PIM on the other hand are enormous, and examples are outlined in this presentation for
wear, mechanical, magnetic, filtration, and electrical components. The critical gain for PIM comes from
the anticipated reduced competition for complex, small shapes. Indeed, several examples are offered to
indicate the possible extension of PIM to a host of new compositions where there is no competition from
standard fabrication routes – implying higher valued added for the PIM producer.
Effect of Variable Thermal Cycling Using Standard MIM Feedstock on Injection
Molding Processing Outputs
Mike Wiseman, Advanced Forming Technology, An ARCMIM Company
The use of regrind during the injection molding process is a generally accepted practice in manufacturing.
In fact, most processing operations generate regrind in one form or another. Compared to plastic, Metal
Injection Molded [MIM] components are generally much smaller relative to overall part size and total shot
volume. As a result, MIM components tend to have runner systems that match or exceed the size of the
part. This material is considered scrap without re-implementation into the molding process.
The necessity for implementing regrind in MIM processing is essential for obtaining revenue and
remaining cost effective. The utilization of only virgin MIM feedstock is impractical. Recommended
regrind percentages are well documented for most thermoplastic materials – rules for MIM are less
understood.
A variety of regrind ratios shall be evaluated using injection molding and material testing techniques.
Correlations between material degradation and processing variation will provide conclusions regarding
allowable regrind usage.
Black Line Prediction for Metal Injection Molding
Anthony Yang, Moldex3D Northern America Inc., Huan-Chang Tseng, Wei-Lun Liao, HsiuChun Lin, CoreTech System (Moldex3D) Co., Ltd., Shun-Tian Lin, National Taiwan University of
Science and Technology, and Chao-Zong Ruan, Shin Zu Shing Co., Ltd. Taiwan
Metal Injection Molding (MIM) that is a novel advanced manufacturing technology with a complex
feedstock consisting of powder and binder can rapidly produces various high precision metal
components. However, the MIM feedstock, including metal power and polymer binder, is more
complicated than conventional thermoplastic injection molding. The so-called black lines are frequently
observed in the surface inspection of shiny MIM articles. In the MIM field, many people are persecuted by
this critical issue; therefore, the commercial Computer Aided Engineering (CAE) software is introduced.
The CAE tool of injection molding has extended to simulate the MIM processing and further provided the
power concentration prediction to present uniform powder dispersion and powder-binder separation. In
this work, using CAE tool (Moldex3D), the predicted low powder concentration areas are related to the
practical black line regions of real case. It will be helpful to understand how to avoid such a surface defect
of MIM articles with brightness.
17-4 PH Review of Atomized Powders for Metal Injection Molding
Tim McCabe, Kinetics
The number of powders available for MIM has been increasing. A series of 17-4 PH powders were
examined to review for use in producing MIM feedstocks. The density, mechanical properties,
microstructure, and slump behavior were analyzed. The balance of these results along with comparison
cost of the powders will be discussed.
Sintering of 316 Stainless Steels at 15 mbar and 400 mbar
Satyajit Banerjee, DSH Technologies, LLC and Claus Joens, Elnik Systems, LLC
A furnace operating with a concentration below the explosive limit of hydrogen has the advantage it does
not have to meet NFPA requirements which gives such a furnace distinct cost advantages. This
presentation compares the properties obtained for the popular MIM 316 type stainless steels, processed
at 15 mbar, which makes the hydrogen concentration below the explosive limit, with those processed at
400 mbar. A comparison of the microstructures and the fracture surfaces for processing under both the
parameters is presented.
Flow Induced Short Carbon Fibers Orientation in Powder Injection Molded Copper
Matrix Composites
Irfan Shirazi and Faiz Ahmad, University Technology PETRONAS, Malaysia
Producing short fiber reinforced metal composite by powder injection molding (PIM) is very attractive. PIM
can provide partial orientation of short fibers in the molded part. Modification in mold geometry can
achieve maximum orientation of short fibers in the flow direction. This study presents developing copper,
carbon fiber mixtures in binder and produce green parts of composites using a specially designed mold to
enhance short fibers orientation in the flow direction. A range of composite mixtures were prepared and
molded, debound and sintered in inert atmosphere. Results showed that more than 90% fibers were
oriented in the flow direction and shrinkage during sintering
Showed slight variation in fiber orientation.
Resonant Frequency Inspection for MIM Components
Gail R. Stultz and Rick W. Bono, The Modal Shop, Inc.
Resonant Inspection is commonly used for quality assurance testing of traditional powdered metal
components, providing a volumetric whole body approach that detects external and internal structural
flaws or anomalies. This technique measures a metal component’s mechanical resonances by striking
the part with an impact and analyzing the acoustic ringing produced. Traditionally, this technique has
been limited to medium-sized components due to the requirements to align and physically impact the
part. Using a new methodology that employs a drop testing fixture to excite the part rather than an
electromechanical impactor, smaller components such as those commonly manufactured by powdered
metal MIM processes can be 100% inspected reliably, quickly and cost-effectively. This paper presents
the new drop test methodology supported with case study and experimental results.
Hardmetals by Using Niobium Carbides (NbC) of Different Stoichiometry and
Process Routes
Mathias Woydt, BAM Federal Institute for Materials Research and Testing, Germany
Hardmetals based on stoichiometric NbC showed recently pronounced wear resistances and competed
with tungsten carbides. NbC has a stability range down to ~NbC0.75. As the solubility of NbC in alloys is
much lower than for WC, liquid phase sintering is not consequently necessary, as for tungsten carbide.
This paper presents a comparison of MIM with cast or metallurgical produced hardmetals under dry
sliding (0.1-10 m/s at 22°C or 400°C) and dry oscillating (2/50/98% rel. humidity) of metal bonded and
SPS sintered NbC and NbC0.9 as well as binderless NbCs versus metallurgically synthesized MMCs with
a very high content of NbC. The metallurgical route is not possible for tungsten carbide due to its high
solubility in alloys.
Advances in Aluminum MIM
Jessu Joyes, United States Metal Powders Inc.
Abstract not available.

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